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Case study: bike shelter project with Lasertube and tube benders
In this article, we explore a real-world example that highlights how the integration of **Lasertube**, **tube benders**, and **wire benders**, along with advanced programming and integration software, significantly reduced both time and material waste in the construction of a bicycle shelter. This case study showcases how modern tube and wire processing systems can enhance efficiency and productivity for **contractors** and **designers** alike.
The project demonstrates how these technologies streamline the fabrication of structures and tubular frames, making the entire process more precise, faster, and cost-effective.
Below are the main steps taken during the optimization of the frame design and production:
- **Project description and design features of the bike shelter**
- **Simplifying connections through the use of joints and bend cuts**
- **Replacing complex sheet metal elements with simpler tubular components**
- **Laser cutting and bending to reduce material consumption**
- **An optimized workflow thanks to BLM GROUP’s MES (Manufacturing Execution System)**
The shelter is an outdoor urban structure designed for bicycle parking. It consists of tubes of various diameters, metal wires, and sheet metal. Initially, the lead time for such a structure using traditional manufacturing methods was estimated at 6 to 8 weeks, with two days dedicated to **component assembly**.
This lengthy assembly phase was primarily due to the use of numerous **welding jigs**, which required careful placement and skilled labor. However, even with experienced workers, the precision of the final product remained limited.
By re-engineering the product and leveraging **BLM GROUP’s Lasertube, tube bending machines, and wire bending machines**, the entire process was streamlined. The result was a **50% reduction in manpower**, **52% decrease in production time**, **26% drop in production costs**, and **20% less material usage**.
One of the key factors in achieving these results was the use of **joints, pass-through holes, hooks, and cut-and-bend parts**, which simplified the frame assembly. These connections ensured accurate positioning of components, making welding easier and improving the overall structural precision.
**ArTube**, the Lasertube programming software, played a vital role by offering a wide range of pre-designed joints and connections that could be applied directly within the CAD model. This made the design and manufacturing process much more efficient.
Additionally, the initial design used cut, bent, and welded sheet metal for support elements. This required three separate machines: a **sheet metal cutting system**, a **press brake**, and a **welding machine**. With **Lasertube technology**, these complex parts were replaced by a single, laser-cut and bent rectangular tube component, reducing the number of machines needed and simplifying the process.
Slots and notches also played a crucial role in the construction of the rack. By incorporating them into the transverse support tube, the need for longer rods was eliminated, further reducing material waste.
Moreover, **All-In-One technology** helped optimize the process by compensating for tube deformation during bending, ensuring accurate laser cuts from the start and eliminating waste.
To learn more about how these technologies can transform your production, visit the **BLM GROUP** website or contact us for detailed information.