Weight Reduction Strategies for Sheet Metal and Machining

Weight reduction in manufacturing is more than just an engineering challenge; it’s a necessity for product developers looking to improve product functionality, boost energy efficiency and reduce overall product costs.

In this blog, we are going to explore effective weight reduction strategies for parts and enclosures manufactured by either sheet metal fabrication or CNC machining and outline the advantages and challenges of each.

But first, why does weight reduction matter? Lightweight designs are crucial for modern products. Whether you’re developing simple electronics housings or advanced aerospace components, reducing weight means enhancing overall performance.

Benefits of Weight Reduction

Here are some quick key benefits of weight reduction in parts and enclosures:

• Reduced Material Usage/Lower Cost: Lightweight designs are typically used to minimize unnecessary bulk of material. By optimizing your design and using materials like aluminum, or high-performance plastics, we can achieve the same strength and durability with less raw material. This will lead to lower material costs.
• Ergonomic Considerations: Lightweight designs are easier to handle during assembly and usage.
• Easier Installation and Maintenance: Lighter enclosures are easier to handle during installation and maintenance. This reduces the risk of accidents or injuries.
• Better Thermal Management: Lightweight materials often have better thermal conductivity, resulting in improved heat dissipation and temperature regulation within enclosures.

Now, let’s compare and contrast on our two main manufacturing processes offered here at Protocase, sheet metal fabrication and CNC machining.

Given the distinct characteristics for each manufacturing process, weight reduction strategies will also differ significantly, so let’s take a look at design strategies for each.

Sheet Metal Fabrication

First off, choosing the right material is the first and most impactful step in reducing weight.

When choosing between aluminum, stainless steel, galvanneal and cold rolled steel for weight reduction in sheet metal designs, aluminum often stands out as the best option. Aluminum is significantly lighter than the other materials while still offering excellent strength-to-weight ratio and corrosion resistance.

However, the suitability of aluminum also depends on specific operational requirements, including environmental exposure and mechanical stress. If higher strength or enhanced durability is required alongside weight reduction, stainless steel or galvanneal may be viable alternatives, albeit they will be slightly heavier.

Secondly, optimizing your design before manufacturing is going to be important. Be sure to design your parts and enclosures with minimum material usage. This can include strategies such as redistributing material where strength is most needed. Here are a few strategies when you’re in the design phase:

• Incorporate cutouts in low-stress areas to eliminate unnecessary material.
• Leverage SolidWorks’ built-in sheet metal tools to accurately design and modify parts and enclosures. Apply features like flanges, hems and jogs to add strength without significantly increasing weight.
• Traditional fasteners like screws and bolts add unnecessary weight and can require additional material for reinforcement. Instead, techniques such as welding or adding rivets can be incorporated to create secure joints with minimal added mass.

CNC Machining

Now, for CNC machined parts and enclosures, there are a few different strategies.

First, unsurprisingly, is to think about your material choice.

• Aluminum is often the top choice for reducing weight due to its excellent strength-to-weight ratio, corrosion resistance and ease of machining.
• Steel, while heavier than aluminum, offers superior durability, cost efficiency and can be ideal for applications requiring added strength over reducing weight.
• Stainless steel provides exceptional corrosion resistance and a polished finish, making it suitable for environments with high moisture or demanding aesthetic standards.

Ultimately, the decision hinges on the balance of weight, cost, durability and environmental factors of the intended use case.

Secondly, think about utilizing hollowing when designing CNC machined enclosures. Hollowing out non-structural areas inside your enclosure can be one of the most effective ways to reduce the weight of CNC machined enclosures. Creating pockets and other features in your design can remove wasted material without compromising the structural integrity of the enclosure.

Lastly, think about adding support structures inside your design. One common method for increasing the durability of an enclosure is to increase the “bulk” or mass of it. Instead of increasing bulk for strength, consider adding support structures to key load-bearing areas. These features provide rigidity without unnecessary weight.

Perform simulations inside your CAD program to identify regions of high stress and strategically place reinforcements only where needed, avoiding unnecessary support that would add weight.

The HVMC Experience

Mastering weight reduction in sheet metal and CNC machined parts and enclosures will require a balance of material science, innovative design principles and a manufacturing process that is powered by High Velocity Mass Customization (HVMC).

At Protocase, we move scientists and engineers past the job-shop model with HVMC, the most major technical innovation in custom manufacturing since the introduction of 3D printing. By blending quality and speed, HVMC makes custom parts at the highest velocity possible. It’s the full spectrum mass customization you need to get your project done as quickly as possible.

If you have any questions, please send a message to one of our account managers. They are always ready and available to help!