Custom steel brackets, from 3D file to welded part

The reference part, start to finish

Our reference part is a six-component bracket: a base plate, a vertical web, two gussets, a shelf and a lug. About one metre of weld in total, all fillet welds.

1. The file. The STEP assembly is broken down into six components, each recognised with its thickness and cutting outline.
2. The welds. The software finds the joints between components and checks that the torch can reach each one.
3. The sequence. It chooses the placement order (base plate first, then the web, the gussets, the shelf), the tack points and the weld order to limit distortion.
4. The cell. One arm picks each component and holds it in position; the other tacks it, then welds once the part is rigid.
5. Inspection. Dimensional and visual check; the part is ready to paint.

Why brackets suit a robot so well

Brackets are often made in small batches, with variants: a longer lug, a moved hole, a different thickness. For a welder, every variant means rereading the drawing and often adapting a jig. For our cell, a variant is simply a new file: the program is recalculated, with no jig to rebuild.

Brackets are also ideal for tab-and-slot design: the components slot together and locate themselves.