Thin machine cover made from light and shape stable material
Thin machine cover made from light and shape stable material
(OP)
Hello,
I would like to explore what options do I have in replacing steel (welded plate + ribs) cover with something much lighter, machinable, stiff and shape stable. Price does not play an important role.
Current welded piece is apprx: 30 x 20 inches, with 0.03" thick base plate, ribs are 0,15 x 0.15"
As mentioned: at approx. 0.8 kg this part is somehow heavy. It is stiff enough not to bend too much when manually handled. I would like to know, if there any options in plastic/carbon range of material, that would allow us to reproduce part with similar mechanical characteristics and yet benefit in weight reduction.
Thanks for all answers in advance.
I would like to explore what options do I have in replacing steel (welded plate + ribs) cover with something much lighter, machinable, stiff and shape stable. Price does not play an important role.
Current welded piece is apprx: 30 x 20 inches, with 0.03" thick base plate, ribs are 0,15 x 0.15"
As mentioned: at approx. 0.8 kg this part is somehow heavy. It is stiff enough not to bend too much when manually handled. I would like to know, if there any options in plastic/carbon range of material, that would allow us to reproduce part with similar mechanical characteristics and yet benefit in weight reduction.
Thanks for all answers in advance.






RE: Thin machine cover made from light and shape stable material
It's not clear from your picture whether there's an overall continuous membrane to the part, or if it has three large windows in it. No effect on mold cost either way.
You might be able to produce a usable part with additive manufacturing, but you may be disappointed with porosity/ incomplete fusion issues. ... or not.
Be clear on this: no plastic is anywhere near as stiff as steel.
Mike Halloran
Pembroke Pines, FL, USA
RE: Thin machine cover made from light and shape stable material
If you redesign the part, you might (MIGHT) be able to consider thermoformed + trimmed plastic. This design path presents a less costly solution than injection molding tools, but only if the total production quantity is suitable. But you do not mention the critical piece of information: bending & flexural allowances. Any plastic part would require a lot of stiffening ribs & reinforcements.
Unless, of course, it is simply something dumb like a decorative fascia.
TygerDawg
Blue Technik LLC
Virtuoso Robotics Engineering
www.bluetechnik.com
RE: Thin machine cover made from light and shape stable material
RE: Thin machine cover made from light and shape stable material
Yes, those are large three windows. And to be even more complicated: size and number of those windows might change: different versions of part will be needed.
Unfortunately this is not a decorative piece and flatness tolerances should be about the same, as achieved with steel welded part (the benefit of still is also possibility of local "manual" bending to correct shape).
Redesign of part, so that details would better suite different material and manufacturing process is not a problem. However: basic shape is defined and can not be changed (size, three windows, total thickness).
I will try to get some more information about additive manufacturing.
RE: Thin machine cover made from light and shape stable material
I do enjoy the problem statements that, at the end, include the requirement that it be identical in every way except performance, and cost is no object (until it is.)
RE: Thin machine cover made from light and shape stable material
Shape is defined by other parts of machine and process in which part is involved. Main shape features are defined.
I of course believe, that steel is optimal choice for this, however I am pushed "from above" to find other - lighter - solutions. On basis of MikeHalloran's comment I have started to search for a workshop that could print it out of some Titanium alloy.
RE: Thin machine cover made from light and shape stable material
Titanium is half as stiff as steel and half the density so unless the section/depth can be increased there will be no improvement for flexure under its own weight. It's main advantage is that the strength is somewhat higher than half and the properties don't change as much with temperature. 0.028 Ti sheet, 24 inch by 36 inch is about $200. 0.035 sheet is about $30 more.
RE: Thin machine cover made from light and shape stable material
RE: Thin machine cover made from light and shape stable material
RE: Thin machine cover made from light and shape stable material
Thanks for all your contribution.
Regarding stiffness: I am happy with current part stiffness. Steel performs well, it does bend during manual operation, but it is all in elastic range. Material currently used is AISI 420.
My task is, to make part with same stiffness and some 30% lighter.
Regarding beryllium that was mentioned: I have never worked with it. Can someone name one of its alloys that could be safely handled? Finish product is constantly in contact with human hands!
RE: Thin machine cover made from light and shape stable material
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RE: Thin machine cover made from light and shape stable material