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Part optimisation | TRUMPF
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Part optimization, key visual

Part optimisation – cleverly designed to make your component more cost effective

What potential is hidden within your parts? Find out now at our workshops and seminars on part optimisation for sheet metal and tubes. Whether you wish to manufacture parts more profitably, produce new parts, or enter new types of technology – the relevant knowledge regarding sheet metal design will help you trim your parts for success, while saving money as well. Because cost-efficiently designed parts are the key to efficient manufacturing, require fewer process steps and reworking, and pave the way to networked production.   

Cost-effective design

Cut down production steps and costs through the function-based redesign of your components.

Apply your skills directly

Learn how to optimise your parts practically through exercises and your own components.

Make use of experience

Take advantage of our practical knowledge from more than 500 workshops.

New inspiration

Acquire rules of design for creative ideas and new solutions.

Sheet metal part design

Lighter, cheaper, or more functional: How would you like your parts? When sheet metal parts have a well-thought-out design, this allows your machines for laser cutting, punching, or bending to reach their full potential – while saving on materials, costs and effort.

Example: optimised axis stop

The axis stop is conventionally produced out of a welded construction with a semi-finished product and milled parts. The many work steps are both time-consuming and cost-intensive. The new design made of two sheet parts reduces the number of parts and thus the joining processes and material usage.

Part optimisation, sheet metal part design, example
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1. Sawing

...all components to size.

2. Milling

... the contact surfaces, oblong holes and stepping.

3. Drilling

... all holes in the components.

4. Welding

... all four components.

5. Laser cutting

... allows for any desired geometries to be cut into sheet metal, and creates bores.

6. Tapping

... for more strength compared to cut threads.

7. Bending

... replaces welding and decreases the number of parts.

8. -46% in costs

... with the new design

Additional examples

Optimised support bracket

The right tricks allow you to design your parts more economically. The solution: reducing the number of single parts and process steps. The support bracket shown here originally consisted of three parts connected with four weld seams, plus separately cut threads. It was redesigned out of just one bending part – without welding. An additional bend even allows you to reduce the sheet thickness and form the threads directly on the punching machine.

Optimised shock absorber bracket

The shock absorber shows how a milled part can become a light bending part. Instead of milling it completely from one block, it now consists of a sheet metal part with three bends. The precision remains.

The following training types are offered

Part consulting

Get the best out of your parts. Work with TRUMPF experts to establish how you can design your parts to be more economical.  Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Technology day

Deepen your production expertise. Whether at your site or at TRUMPF: learn the latest about manufacturing methods, receive an assessment about the status of your technology, and discover the potential for improvement. Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Seminar

Become the expert in your sector. TRUMPF seminars combine part consulting with technology days. You will gain knowledge about processes, production, and design. You will also perfect a sample part as part of a team Duration: 3 days
Speakers: 2
Participants: 1-12
Venue: Ditzingen
Dates: see training calendar

Request information
Workshop

Gain personalised practical knowledge. We look for potential within the parts range in your business. Working together, we will optimise and manufacture selected parts which you can directly implement into your designs and manufacture more cost-effectively. Duration: 2-3 days
Speakers: 2
Participants: 8-12
Venue: by request
Dates: by request

Request information

Laser welding part design

A laser welding system allows you to manufacture for much less than with conventional welding, as long as you identify suitable parts and make these fit for laser welding. You can receive design and manufacturing-related tips and tricks from us.

Example: optimised cover

The conventional cover for electronic components such as electrical cabinets must be sealed and free of distortion. This is the crux with conventional TIG welding, as it results in distortion which must be corrected. The design which is suitable for laser welding replaces multiple work steps: both seam preparation and corrections are no longer necessary, as the lower heat input barely produces distortion.

Part optimisation, laser welding part design, example
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1. Laser cutting

... including free corner cutting.

2. Bending

... ten bends.

3. Welding

Supplementary wire and weld seam thickness compensate for bending tolerances.

4. Grinding/polishing

... as manual work.

5. Laser cutting

... three parts from one sheet.

6. Bending

... eight bends.

7. Laser welding

... with minimal distortion and high optical quality.

8. -30% in costs

... with the design suitable for laser welding

Additional example

Optimised water tank

Up to 90% faster and for noticeably less – without filler material. The water tank shown here demonstrates how a manually welded part can become a cost-effective laser-welded part. Its seams need to be watertight; the laser allows you to weld these in a fraction of the time. The lower heat input also reduces the amount of distortion.

The following training types are offered

Part consulting

Get the best out of your parts. Work with TRUMPF experts to establish how you can design your parts to be more economical.  Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Technology day

Deepen your production expertise. Whether at your site or at TRUMPF: learn the latest about manufacturing methods, receive an assessment about the status of your technology, and discover the potential for improvement. Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Seminar

Become the expert in your sector. TRUMPF seminars combine part consulting with technology days. You will gain knowledge about processes, production and design. You will also perfect a sample part as part of a team Duration: 2 days
Speakers: 2
Participants: 1-12
Venue: Ditzingen
Dates: see training calendar

Request information
Workshop

Gain personalised practical knowledge. We look for potential within the parts range in your business. Working together, we will optimise and manufacture selected parts which you can directly implement into your designs and manufacture more cost-effectively. Duration: 2 days
Speakers: 2
Participants: 8-12
Venue: by request
Dates: by request

Sheet metal fixture design

Fixtures guarantee quality and more reliable processes during laser welding. However, what even experienced practitioners often don’t know is that fixtures are often cheaper and more flexible when they are produced from single sheet metal parts. Additionally, you can reduce production tolerances during welding. When are you going to make work easier for yourself?

Example: optimised fixture made of sheet metal for laser welding

A conventional fixture for laser welding is usually made from a solid milling block. Clamping fixtures made from sheet metal are economically superior to conventionally milled fixtures. This is because they lower manufacturing costs as well as weight. They also allow for additional functions to be integrated and increase heat dissipation.

Part optimisation, sheet metal fixture design example
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1. Sawing

... the raw material of the rod to size.

2. Milling

... all reference surfaces and mounts as well as all through holes and threads.

3. Finishing

... by deburring and anodising.

4. Laser cutting

... any desired geometries and holes.

5. Assembling

... and welding single parts.

6. -17% in costs

... with the sheet metal design.

The following training types are offered

Part consulting

Get the best out of your parts. Work with TRUMPF experts to establish how you can design your parts to be more economical.  Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Technology day

Deepen your production expertise. Whether at your site or at TRUMPF: learn the latest about manufacturing methods, receive an assessment about the status of your technology, and discover the potential for improvement. Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Seminar

Become the expert in your sector. TRUMPF seminars combine part consulting with technology days. You will gain knowledge about processes, production and design. You will also perfect a sample part as part of a team Duration: 2 days
Speakers: 2
Participants: 1-12
Venue: Ditzingen
Dates: see training calendar

Request information
Workshop

Gain personalised practical knowledge. We look for potential within the parts range in your business. Working together, we will optimise and manufacture selected parts which you can directly implement into your designs and manufacture more cost-effectively. Duration: 2 days
Speakers: 2
Participants: 8-12
Venue: by request
Dates: by request

Tube part design

Tubes and profiles are used everywhere – from machine and system construction all the way to the furniture industry. Laser tube cutting saves entire process steps, which allows you to save money. Secure your share of the growing market for laser-cut tubes. You will learn exactly how this works with the appropriate advice.

Example: optimised cantilever

In conventional manufacturing, three parts are adjusted to one another in individual process steps – which is time-consuming and logistically challenging. The cantilever is now cleverly manufactured from two identical tubes with identical shape and dimensions. Both parts are adjusted to one another on a laser tube-cutting machine and then connected together.

Part optimisation, tube part design example
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1. Sawing

... all components to size.

2. Milling

... the contact surfaces, oblong holes and stepping.

3. Welding

... all three components.

4. Deburring

... sawed and milled areas.

5. Laser tube cutting

... the entire assembly with just one clamping.

6. Assembling

... and welding the two single parts.

7. -83% in costs

...through clever connector design.

Additional example

Optimised bend connection

Instead of welding two single parts together to make a corner connection, you can achieve the same result more efficiently using a laser-cut tube with bend connections and positioning aids. Save 31% in costs and produce the component with a laser tube-cutting machine in half the time.

The following training types are offered

Part consulting

Get the best out of your parts. Work with TRUMPF experts to establish how you can design your parts to be more economical.  Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Technology day

Deepen your production expertise. Whether at your site or at TRUMPF: learn the latest about manufacturing methods, receive an assessment about the status of your technology, and discover the potential for improvement. Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Seminar

Become the expert in your sector. TRUMPF seminars combine part consulting with technology days. You will gain knowledge about processes, production and design. You will also perfect a sample part as part of a team Duration: by request
Speakers: 2
Participants: 1-12
Venue: Ditzingen
Dates: see training calendar

Request information
Workshop

Gain personalised practical knowledge. We look for potential within the parts range in your business. Working together, we will optimise and manufacture selected parts which you can directly implement into your designs and manufacture more cost-effectively. Duration: 1 day
Speakers: 2
Participants: 8-12
Venue: by request
Dates: by request

Request information

Tube fixture design

Would you like to increase your vertical range of manufacture, improve your machine utilisation rate, or lower the costs for fixtures? Then you should manufacture fixtures from laser-cut tubes in the future. It’s easier than you think.

Example: optimised fixture made of tubes

The numerous milled parts in the conventional fixture are both time-consuming and cost-intensive. The costs of chipping manufacture are high and fits for pins and threads are necessary. The assembly must be welded when it is lying down. A tube plug-in design replaces the entire milling block. Its advantages: fewer parts, less effort. The vertical design of the fixture also makes it easily accessible and ergonomic.

Part optimisation, tube fixture design example
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1. Sawing

... raw materials, various semi-finished products and dimensions.

2. Milling

... all surfaces which are to be bolted or joined.

3. Drilling

... precision fits, through holes and threads.

4. Laser tube cutting

... parts including all inner geometries and joining aids in pin form.

5. Assembling

... and welding the two single parts.

6. -80% in costs

... with flexible tube design.

The following training types are offered

Part consulting

Get the best out of your parts. Work with TRUMPF experts to establish how you can design your parts to be more economical.  Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Technology day

Deepen your production expertise. Whether at your site or at TRUMPF: learn the latest about manufacturing methods, receive an assessment about the status of your technology, and discover the potential for improvement. Duration: 1 day
Speakers: 1
Participants: 1-6
Venue: by request
Dates: by request

Request information
Seminar

Become the expert in your sector. TRUMPF seminars combine part consulting with technology days. You will gain knowledge about processes, production and design. You will also perfect a sample part as part of a team Duration: 2 days
Speakers: 2
Participants: 1-12
Venue: Ditzingen
Dates: see training calendar

Request information
Workshop

Gain personalised practical knowledge. We look for potential within the parts range in your business. Working together, we will optimise and manufacture selected parts which you can directly implement into your designs and manufacture more cost-effectively. Duration: 2 days
Speakers: 2
Participants: 8-12
Venue: by request
Dates: by request

Request information

Which part are you starting with?

The first step is very easy: talk to us. Together we will come up with ideas for how you can take full advantage of the potential within your parts.

Contact

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Contact
Dominik Straus
Consultation for part design
Telephone +49 7156 30332794
E-mail
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Part optimisation – cleverly designed to make your component more cost effective
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