1. Minimize the number of parts
Find ways to assemble parts. For example, many electronics enclosures use movable hinges instead of knuckle hinges. When routing, select a molded guide feature, or use a thermoformed guide (such as an old LazerTag gun). Speaking of minimizing the number of parts
2. Built in fasteners
Whenever possible, build assembly features directly into the part instead of using screws. Snap fit is usually equally safe and can be assembled without tools. Sometimes screws are necessary, but the economical use of fasteners may consume up to 50% of the assembly labor. It should be noted that the snap fit may increase the cost of the injection mold, so it is important to design the part as injection friendly.
3. Use rubber roll parts
It's great to be a product designer now. Many of our design problems have been solved! Previously, each thread had to be carefully designed, but now hundreds of standard diameters and pitches can be selected.
This goes far beyond the basic nuts and bolts. Cots cover most of the functions of spring, pin, motor, microcontroller, sensor and gear design. This not only allows you to focus on unique challenges, but also means that the manufacturing team has the tools and skills to assemble your design.
4. Use the same parts throughout the design and product family
Warning on rubber roller parts: it is not enough to use standard screws only. I have designed a robot component, one part of which has M5 x 10 mm socket head cap screws, the other part is M4. Design a 5 x 12 mm hex head screw on the other part.
I have to switch between assembly tools frequently; It is easy to confuse which screw will go where, which is a very bad idea. Don't follow my example: Standardize parts not only on each component, but also on the entire product line. Where possible, a single tool should be used for the entire assembly.
5. Use modular design
An important application of cots and ordinary parts is modularization, which decomposes the design into smaller sub assemblies and can be used for a variety of products. Think about your first computer: you can put some pre assembled parts together - the motherboard, the hard disk, the video card, it's easy. Another advantage is that modular design is not only good on the assembly line; They also help you extend the use time of the product on site by facilitating maintenance and upgrading.
