pic: One piece sheet metal chassis concept
 

Re: pic: One piece sheet metal chassis concept
 

I'm curious as to how this would be bent into shape. Would it not intersect the brake?

Re: pic: One piece sheet metal chassis concept
 

You do realize that this has to be manually bent. That's why most teams have to use multiple pieces, just so that you can physically bend it like arpan said.

Re: pic: One piece sheet metal chassis concept
 

I'm not sure how one would even bend this manually... unless it were made of paper.

Re: pic: One piece sheet metal chassis concept
 

Well, there's always 3D printing :rolleyes:

Haha, anyways OP, the design effort and practice is great. Keep it up.
Just remember though- one of the most important parts of design is keeping in mind the fact that you have to actually be able to make it. (At least if you want the design to actually be of use...)

Re: pic: One piece sheet metal chassis concept
 

I am not sure how feasible a one part assembly would be for most schools or teams - but I do like where you are going with this.

Even if it was a 3 part assembly, it would provide for great learning opportunities for the students.

It would be cost-effective, light-weight, and offer many other advantages.

Keep us up to date on your advances - and great work!

Re: pic: One piece sheet metal chassis concept
 

I think a can modify this design to make it possible to be bent from one piece.

Re: pic: One piece sheet metal chassis concept
 

What would be the benefit? The improvement in overall strength would be negligible, and it would make putting the robot together much more difficult. Using rivets to attach pieces of sheet metal works well, it is fairly easy and quick to do, and it allows you to assemble modules of parts together before bringing it all together.

-Nick

Re: pic: One piece sheet metal chassis concept
 

there's no real benefit; I just thought it was an interesting proof of concept.

Re: pic: One piece sheet metal chassis concept
 

This would actually be a really interesting project to learn what must be taken into account by the designer before handing off to the fabricator. I worked in a production plant briefly where Mechanical Engineers made CAD models to be fabricated by the in house shop. The first couple things they designed would often not take into account the fabrication nuances of the shop and thus, the shop could not make them.

Most college courses that I know of don't bother to teach the necessity of designing something that is both reliable and fabricate. The best designs come from a close relationship between engineer and technician.

Re: pic: One piece sheet metal chassis concept
 

As a non-CADer and non-engineer, I found it interesting to think about. I agree that it's probably not the ideal way to create a chassis, but it looked like a fun challenge. Do you have an image of the metal CADed before bended?

Re: pic: One piece sheet metal chassis concept
 

Harder than how you will machine something in my opinion is assimilability. Making sure you can get your hand into something or the space in front of a bolt is accessible by whatever tool is needed for it. That can be one of the worst time wasters when building something and is one of the easiest things to miss.

Re: pic: One piece sheet metal chassis concept
 

Actually, there may be no or small benefit from a robot-standpoint (I haven't seen your one-piece design) but there is benefit from an engineering standpoint.

As a working ME that designs products, I've been trained that you nearly alway save money-- in total part cost, in assembly time and in ordering and handling cost--if you can reduce parts-count. This is a normal part of DFMA training. (design for manufacture and assembly) Granted, unlike the above image the part Does have to be able to be made with regular equipment. Occassionally multi-part versions are more cost effective, but not usually.

Further, another 'trick' when bending sheetmetal--if the bend line doesn't require as much strength, you can perforate it to remove metal and then hand-bends really are possible even if not 'easy.'

Part of why we're here in First is to teach future engineers--so I say if you can do it in one piece, i say "name that tune".

Re: pic: One piece sheet metal chassis concept
 

I'm not quite sure what you are asking. This is the CAD.

If the modification below is made, I think this part can be bent much more easily.
https://drive.google.com/file/d/0B3b...it?usp=sharing

Re: pic: One piece sheet metal chassis concept
 

Do you have the version without the bends on it, ie the flat part.