In this article, a real-world case study is presented to demonstrate how the use of **Lasertube**, **tube benders**, and **wire benders**, along with advanced programming and integration software, significantly reduced time and material waste in the construction of a bicycle shelter. This project highlights how **contractors** and **designers** can benefit from modern tube and wire processing systems to **streamline the fabrication of structures and tubular frames**.
The following are the key steps taken during the optimization of the frame design and production:
- **Project description and design features of the bike shelter**
- **Simplifying connections through the use of joints and bend cuts**
- **Replacing complex sheet metal elements with simpler tubular components**
- **Laser cutting and bending to minimize material usage**
- **An optimized process enabled by BLM GROUP’s MES production management system**
The shelter is an outdoor urban structure designed for bicycle parking, featuring tubes of various diameters, metal wire, and sheet metal. Under traditional manufacturing methods, the lead time for such a structure typically ranges from 6 to 8 weeks, with 2 days dedicated solely to **component assembly**. This lengthy phase often involves the use of numerous **welding jigs**, requiring precise placement and skilled labor, which limits the overall precision of the final product.
Thanks to **BLM GROUP’s Lasertube**, **tube bending machines**, and **wire benders**, the entire production process was re-engineered, leading to a **50% reduction in manpower**, **52% decrease in production time**, **26% lower production costs**, and **20% less material cost**.
By using **joints, pass-through holes, hooks, and cut-and-bend parts**, the construction of the frame became more efficient. These connections ensure accurate **component positioning**, making assembly and welding easier and improving the overall structural precision. The **ArTube** software played a crucial role in this process, offering a wide range of pre-defined joints that could be applied directly within the CAD model.
Instead of relying on three separate machines—**sheet metal cutting**, **press brake**, and **welding**—the project now uses a single **Lasertube system** to produce complex components from rectangular tubes. This not only simplifies the process but also reduces the need for multiple tools and operators.
Slots and teeth were also used in the transverse support tube to accommodate bent tubes and rods that hold the bikes. This design choice helped reduce the length of the rods, saving **material** while maintaining structural integrity. Additionally, **All-In-One technology** ensured that laser-cut and bent parts were produced without waste, compensating for any deformation caused by the bending process.
For more information on how these technologies can transform your production, feel free to reach out. We're here to help you streamline your workflow and achieve greater efficiency.
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