Attaching large and small metal parts together

[massachiramona]

What are various attachment that I can build into a design to avoid having to weld parts together? I understand how to create threads. For heavier parts that are vertical and horizontal to each other is there a reference guide of different ways to attach parts? Hidden attachments would be more useful but any mechanism would be appreciated.  Thank you in advance for any reference materials.

[laughingcreek]

oh man, your talking about literally millions of different possibilities.   i could just refer you to the mcmaster carr catalog.

the objects in question, how the connection needs to function, and under what types of load would all be helpfull to give you a more targeted answer

[chrisplyler]

Threaded fasteners?

Expansion type fasteners?

Friction type fasteners?

Direct threading of Part A into Part B?

Adhesives?

Spring retention type clips?

Some sort of "over center" locking mechanical assembly?

Suspended with chain, cable, tie wire, etc.?

Magnets?

Snap-on or snap-over connectors? (does this fall into the spring clip category?)

Suction cups?

Hook/eye (single pair) or hook/loop (like Velcro)

Surface tension of a fluid? ("lick it and stick it")

Sewing/stitching?

Active laser beam position holding?

Use The Force, Luke?

[massachiramona]

Thank you for your reply. I am making organic shapes and structures from a foot long I think I will be using aluminum as the metal because it is light. Also making smaller objects sconces. I am walking blind into this so a tutorial would help. I want to limit any welding because then there is added cost.  

[massachiramona]

I'm going to look up all of these suggestions. I replied with a few photos to the previous response if you get a chance to take a look. A few tutorials on different ways to attach parts would be useful. Thank you for your help.

[TrippyLighting]

It looks like the metal parts are pretty intricate and would warp out of shape through welding anyway.

Are you attaching these metal decorations to curved surfaces ? I am not sure I am getting what you are trying to communicate with your second image. Is this an object you would attach these metal parts to?

Are the aluminum parts natural, untreated metal surface or anodized?

[massachiramona]

I would be attaching the intricate pieces together.  Here is a better view. I would like them to be three dimensional. I want them to be hung from a ceiling with metal wire and the needed attachments. I would like to have LED lights go around them. I think they will be natural in the beginning of production. Getting them anodized would cost a fortune.  I would like the entire structure to be 3 feet or more long but cost effective to consumers if needed I can create designs to be smaller. I can come up with a million ornamental designs but if I don't understand how to attach them and how to create housing for the lighting my ideas are of no use.  

[TheCADWhisperer]

There is probably not any benefit in trying to "reinvent the wheel", unless you want to come up with something novel and never before seen by man, woman or beast.

Look around you and observe what other people have done with similar designs.

(If we are ever permitted to go back to the store again...)

[etfrench · Accepted solution]

Here's a couple of ideas:

1. Make the fastener part of the design.  For example: Countersink a bolt, then use a plug of contrasting material to cover the hole.
2. Use tapered pins of the same material.  Sanded/filed smooth, they can be virtually invisible.  See Clickspring's youtube channel.

p.s. Use the Simulation environment in Fusion 360 to determine if your designs will be stable.

[chrisplyler · Accepted solution]

One easy option in some circumstances might be a sort of dove-tail joint assembly with a set screw...if you've got enough room to fit a little hex wrench in.

But really, the scope of your question is beyond the intent of a Fusion 360 forum.

@TrippyLighting... if you make any kind of example model for this thread, it had better light up!

[massachiramona]

Thank you, Brilliant. What about something like this? How do I make sure it is sturdy and not fall on peoples heads? Also any references you could suggest on LED Bi-pins and socket attachments. How do I prepare the sculptures to be equipped with the housing to accommodate the parts? Thank you for your help greatly appreciated.

[chrisplyler]

Seriously? I'm not an engineer.

Which part is in danger of falling on a person's head? How much does it weigh? What are the dimensions? What will be the orientation? What is the material?

I have no knowledge of LED pins or sockets.

Are you looking for help with operating Fusion 360? Or are you looking to commission product design?

[etfrench]

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@massachiramona wrote:

How do I make sure it is sturdy and not fall on peoples heads?

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See post #9: Simulation Workspace

[TrippyLighting]

Can you try to explain the complete scope of what you are trying to accomplish?

Pick one project and then let's move forward with that.

What is the scale of such objects?

[massachiramona]

I think I understand from the replies from chrisplyer to create a dove-tail joint assembly with a set screw and etfrench to create countersink bolts. Both can work and are simple to incorporate. My question for you as a lighting designer is where do you get your understanding from how to assemble your lighting? Any resources that an amateur like me can use? I used to buy all my lighting parts from distributors and then do all the wiring myself, but constructing the housing to hold the sockets and LED pins is overwhelming me. I think if I saw a few examples it would just register and I would be able to apply the concepts to different structures. 

[TrippyLighting · Accepted solution]

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@massachiramona wrote:

... My question for you as a lighting designer is where do you get your understanding from how to assemble your lighting? ...

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Don't let this discourage you. I've been a mechatronics engnieer for almost 30 years 😉

While I don't design and build these systems for a living (yet) my professional history has informed many of the design choices.

[chrisplyler · Accepted solution]

It is not entirely uncommon, when a product designer is planning to incorporate off-the-shelf parts from another supplier, to ask for submittal sheets / data sheets / etc., or heck, even order a couple of the parts to take measurements off of and test with. Perhaps you should get your hands on these pins and sockets and LEDs that you intend to use, so that you can have them in front of you while you're making design decisions that will relate to them. Or perhaps order another supplier's assembly that incorporates same, so you can see how they did it.