[mplanchard]

Hi Aren

I don't have access to download your beautiful model tonight but I can still comment based on the images. I assume you received your 2010-2011 robot sponsorship package. 2010 has many new enhancements to sheet metal so I would go through the sheet metal tutorial and weldment tutorial

I think your outside holes are too close to the edges. Rule on thumb 3times the hole radius to the edge.

Also don't change your hole diameter unless you really have to.

Find out from your nearest friendly sheet metal shop what standard tools do they keep at the ready. That way you are not asking for custom tools or ones they have to search for

If you can make this model I know you can do a simple stress analyst on the part. You know the weight of the tough box on other sub assembly. Go to the Evaluate tab and select on SimulationXpress. Select the cylindrical face of the holes along the outside to be fixed. Select the top face to apply the force. This Will be a rough approximation. But it will show you areas of high stress.

Also in the Evaluate tab use SustainabilityXpress to set a baseline with your current material and then select Find Similar to search for materials of similar tensile strength. There may be another material that costs less and is better for the environment too. Marie