CNC-Ready Mechanical Design Optimisation
Budget: $30 – $250 AUD
I have an existing mechanical design concept that should work in principle, but seems relatively complex, and I am interested to have a mechanical engineer look at the requirements and determine if any improvements can be made to reduce complexity and ease manufacture.
The part is an addition to a prior project, which consists of an aluminium clamp that is used to hold a telescopic pole, which in turn is strapped to a street pole/road sign. See pdf file for details.
The main issue is the need to use ratchet straps. These are awkward because they have a long strap, which is hardly ever used, as road side poles are only about 60mm in diameter, and these are expensive because they have a feature missing from most straps - the ability to lock them with a padlock. The new design is meant to eliminate these issues, while providing a much faster and simpler rig up at lower up front and maintenance cost.
Your task is to take my current CAD (inventor files or STEP), propose any conceptual changes, and consider areas to simplify the model so it is genuinely CNC and cost-friendly.
The priorities are clear. First, validate the concept—show me that the key movements and load paths still behave once real-world fits and clearances are applied. Then, simplify: reduce part count where possible, merge features that add cost but little function, and call out any geometry that will drive cycle time or scrap risk.
We’ll be cutting in metal on a 3-axis mill to start, with the option to step up to 5-axis later, so the redesign needs to respect common tool diameters, available fixturing, and sensible GD&T. I’m happy for you to suggest finishing operations or alternative alloys if that unlocks a stronger, lighter, or faster-to-machine result, provided the end product stays robust.
Deliverables I need at hand-off:
• Updated native CAD files and neutral STEP.
• A concise drawing pack with critical dimensions, tolerances, and surface call-outs.
• A short DFM report highlighting how each change cuts time, cost, or complexity.
The part is an addition to a prior project, which consists of an aluminium clamp that is used to hold a telescopic pole, which in turn is strapped to a street pole/road sign. See pdf file for details.
The main issue is the need to use ratchet straps. These are awkward because they have a long strap, which is hardly ever used, as road side poles are only about 60mm in diameter, and these are expensive because they have a feature missing from most straps - the ability to lock them with a padlock. The new design is meant to eliminate these issues, while providing a much faster and simpler rig up at lower up front and maintenance cost.
Your task is to take my current CAD (inventor files or STEP), propose any conceptual changes, and consider areas to simplify the model so it is genuinely CNC and cost-friendly.
The priorities are clear. First, validate the concept—show me that the key movements and load paths still behave once real-world fits and clearances are applied. Then, simplify: reduce part count where possible, merge features that add cost but little function, and call out any geometry that will drive cycle time or scrap risk.
We’ll be cutting in metal on a 3-axis mill to start, with the option to step up to 5-axis later, so the redesign needs to respect common tool diameters, available fixturing, and sensible GD&T. I’m happy for you to suggest finishing operations or alternative alloys if that unlocks a stronger, lighter, or faster-to-machine result, provided the end product stays robust.
Deliverables I need at hand-off:
• Updated native CAD files and neutral STEP.
• A concise drawing pack with critical dimensions, tolerances, and surface call-outs.
• A short DFM report highlighting how each change cuts time, cost, or complexity.