Key principles.
Consolidation
Combine parts where possible. 3D printing enables.
Stack-up
Distribute tolerance across mating parts.
Lead-in chamfers
Chamfered insertions for robot/manual assembly.
Single way
Orient features so part assembles single way only.
Off-shelf
Standard fasteners reduce inventory.
Snap-fits
Eliminate fasteners with snap-fits where possible.
FAQ
Manual labor $30-100/hour. Automation $10-30/hour amortized. Reduce assembly time = save cost.
Multiple parts mating. Worst case = sum of tolerances. RSS = √(sum of squares). RSS more realistic.
Lead-in chamfers (45° × 1mm typical). Robots can position to ±0.1 mm; chamfer handles error.
Combine parts where possible. 3D printing enables impossible-to-machine consolidation.
M3-M10 metric most common. Avoid custom unless needed. Standard saves cost throughout supply chain.
Higher volume justifies investment in automation, custom fasteners, tooling.
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