Application 1: sheet metal buttons and user interface panels
Design tip: sheet metal is a low-cost option for manufacturing custom interface panels for integration into off the shelf components. Special fasteners for sheet metal (such as PEM brackets and inserts) are an effective method to add threaded holes and bosses to thin sheet metal parts (as shown in the above figure).
Application 2: assembly tools and Fixtures
Design tips: Aluminum 6061-T6 and Polyoxymethylene (POM) and other materials are often used in assembly tools because of their relatively low cost and easy machinability. Polyoxymethylene (POM) is also a good choice to prevent damage to interface components or when low friction is required.
Application 3: mass simulation and vibration test fixture
Design tips: since flight is a non-static environment, electromechanical components and payloads are often subject to high-frequency vibration. The effect of this vibration is difficult to simulate, so physically accelerated life cycle test on the vibrating plate is usually a key step.
When designing fixtures, please keep in mind that vibrating tables usually have strict weight restrictions to ensure safe operating parameters. The smaller the mass of the fixture, the larger the test component.
Application 4: machined aerospace structures and fuselage components
Design tips: the equal mesh structure can effectively reduce the total weight, while maintaining stiffness and ensuring uniform planar material properties. However, this strategy will significantly increase machine time and reduce costs. Use isogrid structures only when weight reduction is critical, and implement other strategies to facilitate manufacturing, such as using the largest possible corner radius.
Application 5: Avionics and sensor housings
Design tips: machined housing is a good way to protect fragile sensors (such as commercial cameras) from harsh environments. In order to reduce weight, aluminum alloy is a commonly used material. Anodic oxidation coating is an effective method to protect machined parts from corrosion, while providing a harder, wear-resistant outer surface.
According to specific requirements, Mil-A-8625, type 2 or type 3 hard coated anodizing can provide the most durable finish. However, anodizing will reduce the fatigue strength of aluminum alloys, so it is necessary to carefully analyze the components that bear cyclic loads.