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grabcad

To achieve cost savings through enhanced manufacturing efficiency, my design employs high-quality materials and techniques. I crafted an Aluminum 6063 extrusion profile manually for optimized production. The die cost is estimated at $1000-$1500, with lower extrusion costs when purchasing in bulk. This design also offers long die use due to precise tolerancing. Instead of welding, I propose bolting or riveting components to the main beam, which significantly reduces costs compared to the original welded design. For battery box mounts, I suggest using bent laser-cut aluminum sheets, a cost-effective method. While maintaining common fasteners for sole bar attachment, this redesign minimizes expenses without sacrificing weight. With more resources, I would implement topology optimization for better load distribution, forged aluminum for mounts, and refine the aesthetic details.