custom brake bracket outsourcing waterjet or CNC

[sleepydad]

First off I have never really done this kind of thing but... it seems I get contacted once or twice a month by people looking for the brake bracket I did based on [MENTION=53470]Rockdawg84[/MENTION] initial work.

<a href="https://imgur.com/J1IjCog"><img src="https://i.imgur.com/J1IjCogl.jpg" title="source: imgur.com" /></a>

complete write up here
http://www.toyota-4runner.org/3rd-gen-t4rs/247329-2000-limited-sleepydad-build-2.html#post2866745

I have spoken to a couple of machine shops locally and the first 2... even though they said small part runs are fine.... are telling me if it needs to be at least 500K worth of orders or it's too small. ok fine. I guess my idea of small parts runs was not on par with theirs. They were really nice and gave me a couple of other leads.

I know some members here have done this type of thing. Can somebody share some wisdom, I'm really not wanting to get into the parts business but I'm going to make another couple of sets of these brackets for myself so... I figured I would do a small batch because my guess is setup is the big cost and once it's setup they unit price should come down substantially.

any help, please advise?

 

[I_bRAD]

First off I have never really done this kind of thing but... it seems I get contacted once or twice a month by people looking for the brake bracket I did based on [MENTION=53470]Rockdawg84[/MENTION] initial work.

<a href="https://imgur.com/J1IjCog"><img src="https://i.imgur.com/J1IjCogl.jpg" title="source: imgur.com" /></a>

complete write up here
http://www.toyota-4runner.org/3rd-gen-t4rs/247329-2000-limited-sleepydad-build-2.html#post2866745

I have spoken to a couple of machine shops locally and the first 2... even though they said small part runs are fine.... are telling me if it needs to be at least 500K worth of orders or it's too small. ok fine. I guess my idea of small parts runs was not on par with theirs. They were really nice and gave me a couple of other leads.

I know some members here have done this type of thing. Can somebody share some wisdom, I'm really not wanting to get into the parts business but I'm going to make another couple of sets of these brackets for myself so... I figured I would do a small batch because my guess is setup is the big cost and once it's setup they unit price should come down substantially.

any help, please advise?

Waterjet is a good idea, or laser cut.

 

[weekendclimber]

Sub'd

 

[phattyduck]

Eimkeith might be the right guy to contact - unless you are looking to make money on this. He could probably offer these...

-Charlie

 

[turbo8]

If it is just flat plate\sheet, get them waterjetted\lasered.

Do you need threaded holes or studs\inserts pressed in?

www.heroldprecision.com/

 

[thegipper]

I work at a metal fab shop with 4 lasers, press brakes, certified welders and a water jet.

If you want, PM a drawing and I can have our estimator quote it. Make sure you specify what quantities you are looking for.

Most shops will charge and arm and a leg for small orders, rightfully so (setup time, programming time etc). Usually when a shop doesn't want the work (not worth their time), they will jack the price up so high that it turns most people away unless you REALLY want/need it.

BTW. That part can easily be laser cut, no need for water jet (water jet is much more expensive to run).

We even have equipment that will scan the part and make a CAD file.

 

[sleepydad]

If it is just flat plate\sheet, get them waterjetted\lasered.

Do you need threaded holes or studs\inserts pressed in?

www.heroldprecision.com/

no it's a very simple deal, and I used some custom 4mm spacers to get the caliper/pads centered on the rotor. by hand it was all caveman style.

<a href="https://imgur.com/DiubK6x"><img src="https://i.imgur.com/DiubK6xl.jpg" title="source: imgur.com" /></a>
<a href="https://imgur.com/sfgiYAX"><img src="https://i.imgur.com/sfgiYAXl.jpg" title="source: imgur.com" /></a>
<a href="https://imgur.com/oJVoneg"><img src="https://i.imgur.com/oJVonegl.jpg" title="source: imgur.com" /></a>

 

[sleepydad]

I work at a metal fab shop with 4 lasers, press brakes, certified welders and a water jet.

If you want, PM a drawing and I can have our estimator quote it. Make sure you specify what quantities you are looking for.

Most shops will charge and arm and a leg for small orders, rightfully so (setup time, programming time etc). Usually when a shop doesn't want the work (not worth their time), they will jack the price up so high that it turns most people away unless you REALLY want/need it.

BTW. That part can easily be laser cut, no need for water jet (water jet is much more expensive to run).

We even have equipment that will scan the part and make a CAD file.

thanks I think I'm just going to run out and get it scanned tomorrow at a local place. that would give me some more options. I have done tons of google sketchup but I know that is just free software nobody would run a business on and I don't have any decent CAD stuff. I have done cabinet work and it's pretty much the same story. people would want 1 custom cutting board... people, just find one on amazon. I can't even buy the lumber locally for the prices they are asking.

everybody was very upfront with me about that... it makes sense. if you have steady business and your regular customers are bringing in large orders your already setup to run.

I think I found a guy who can do it local for a decent price.

 

[I_bRAD]

thanks I think I'm just going to run out and get it scanned tomorrow at a local place.

Can you get a copy of Autocad on the line? Most shops should take a DXF or DWG file no problem.

Perhaps modern systems are more forgiving, but depending on the resolution of the scan it might create a poor pattern for programming the machine. Think hand drawn line with all it's imperfections vs a line defined by an equation.

Once you get that far, figure out your nesting- how the individual pieces are laid out on the plate, so you can maximize your material usage.

With that all figured out, you should get much better quotes as you've done a good chunk of the work yourself.

 

[sleepydad]

Can you get a copy of Autocad on the line? Most shops should take a DXF or DWG file no problem.

Perhaps modern systems are more forgiving, but depending on the resolution of the scan it might create a poor pattern for programming the machine. Think hand drawn line with all it's imperfections vs a line defined by an equation.

Once you get that far, figure out your nesting- how the individual pieces are laid out on the plate, so you can maximize your material usage.

With that all figured out, you should get much better quotes as you've done a good chunk of the work yourself.

the problem is autocad is $4000+ USD

 

[I_bRAD]

the problem is autocad is $4000+ USD

You are technically correct! If you're paying for it, I recommend solidworks.

Edit- I've never tried this software but it seems to be a non-pirated way to create DXF files for free:

https://librecad.org/

 

[sleepydad]

You are technically correct! If you're paying for it, I recommend solidworks.

Edit- I've never tried this software but it seems to be a non-pirated way to create DXF files for free:

https://librecad.org/

I'm going to stop over at a place today and they are going to scan the bracket part. so I will have a CAD file....

then I found a guy locally who probably can do them for $25-$40 each... of course I will probably have to get 100 of them made

I will see if I can get him to do 50 of them... that would make 25 pairs and I think I might be able to stomach it.

 

[turbo8]

You can get a free version of Draftsight (made by the people that make Solidworks) It is similar to Autocad. Files are .dwg\.dxf

https://www.3ds.com/products-services/draftsight-cad-software/

Once you have a 3d file, you can try online prototyping sites, like www.xometry.com. You will get a quote instantly.

 

[derpiful]

A few recommendations:

Try out Fusion360 for CAD. It's pretty easy to learn and use, and they have a free license for startups/hobbyists. For this you're definitely going to want a .dxf to send out.

I would try to look around for a few quotes. I recently got a one-off 1/4" 5052 aluminum plate with 10 holes and similar dimensions waterjet for ~$20.

 

[sleepydad]

A few recommendations:

Try out Fusion360 for CAD. It's pretty easy to learn and use, and they have a free license for startups/hobbyists. For this you're definitely going to want a .dxf to send out.

I would try to look around for a few quotes. I recently got a one-off 1/4" 5052 aluminum plate with 10 holes and similar dimensions waterjet for ~$20.

fusion360 is super easy I agree I was able to do almost anything I wanted in about an hour. although I can't quite figure out the free license part and the export only really has a couple of types. nothing .dxf at all

IGES, SAT, SMT, STP or STEP are the only export types.

can you take a look?

this is the bracket I cleaned it up.
https://drive.google.com/file/d/16wrX767cCdQXFFQb84Lqw700pteoMpqG/view?usp=sharing

this is the spacer
https://drive.google.com/file/d/1EQVWsaiEhXBX5a3lKluBWvq9Im7r469C/view?usp=sharing

I can't seem to get any quotes for less than $250 each for the bracket and even the simple spacer they want $180 each.

if that is really how much it costs.... I will just grind them out by hand again but that would really suck.

any help is appreciated?

 

[sleepydad]

You can get a free version of Draftsight (made by the people that make Solidworks) It is similar to Autocad. Files are .dwg\.dxf

https://www.3ds.com/products-services/draftsight-cad-software/

Once you have a 3d file, you can try online prototyping sites, like www.xometry.com. You will get a quote instantly.

it's the same story all over.

no I don't need thousands of these parts...

xometry the bid came in at $280 per bracket

emachineshop came in $73 per bracket or $146 for a set
Material: Steel A36 Hot rolled
Thickness: 0.370" +/- 10%
General Tolerance: +/- 0.02"

so actually... emachineshop might be a possibility?

 

[turbo8]

In your file, there are little cut marks, do those need to be in there?
xometry software will see those cuts and add a lot to the cost.

Attached is dxf file and a new file with the cuts removed.

 

[sleepydad]

In your file, there are little cut marks, do those need to be in there?
xometry software will see those cuts and add a lot to the cost.

Attached is dxf file and a new file with the cuts removed.

yes if you look at this post back 1 page... I cleaned things up. this the file I used for quotes.

http://www.toyota-4runner.org/3rd-g...ket-outsourcing-waterjet-cnc.html#post3187791

 

[turbo8]

yes if you look at this post back 1 page... I cleaned things up. this the file I used for quotes.

http://www.toyota-4runner.org/3rd-g...ket-outsourcing-waterjet-cnc.html#post3187791

attached is the dxf of the cleaned up file.

 

[sleepydad]

attached is the dxf of the cleaned up file.

ok but... what does a dxf file get me?

I was able to upload the .step file and everybody was able to use it... forgive my ignorance, I have not done this kind of stuff before. I had high hopes given all the advancements and automation but it seems machine shops still work like they did 20 years ago.

either your rich and just pay for things to be made, or you work at a machine shop and have access to the tools and maybe you sneak in some of your own work.

I guess for the rest of us we just continue to cut things out manually or find a crazy friend who has a mill in their garage.

I do appreciate any insights I can get to hopefully figure out an economical approach to get these kinds of very simple parts made without it costing an arm and leg.