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In this article, a real-world example is explored to demonstrate how the implementation of **Lasertube**, **tube benders**, and **wire benders**, along with advanced programming and integration software, significantly saved time and reduced material waste in the construction of a bicycle shelter. This case highlights how modern tube and wire processing systems can help **contractors** and **designers** streamline their fabrication processes and improve efficiency when building structures and tubular frames.
The project showcases a practical approach to optimizing both design and production. Below are the key steps that were taken during the re-engineering process:
- **Project description and design features of the bike shelter**
The structure is an outdoor urban solution for bicycle parking, composed of tubes, metal wires, and sheet metal. Initially, the lead time was expected to be between 6 to 8 weeks, with two days dedicated to assembly due to the use of numerous welding jigs. However, this lengthy and complex process often led to limited precision and high labor costs.
- **Simplifying connections through the use of joints and bend cuts**
By using **joints, pass-through holes, hooks, and cut-and-bend parts**, the frame assembly became more straightforward. These connections ensured precise positioning, making welding easier and improving overall structural accuracy. **ArTube**, the Lasertube programming software, played a crucial role by offering a library of pre-designed joints that could be applied directly to the CAD model.
- **Replacement of complex elements made of sheet metal with simpler tubular elements**
In the original design, support elements were created using multiple machines: a **sheet metal cutting system**, a **press brake**, and a **welding machine**. With **Lasertube technology**, these components were replaced by single-piece rectangular tubes that were **laser-cut and bent**. This not only simplified the manufacturing process but also reduced the need for multiple machines.
- **Laser cutting and bending to reduce material consumption**
The use of **slots and teeth** on transverse support tubes allowed for better alignment and reduced the length of supporting rods, leading to significant material savings. Additionally, **All-In-One Technology** helped eliminate waste by adjusting cutting geometries to account for tube deformation during bending, ensuring accurate results from the start.
- **An optimized process thanks to BLM GROUP's production management MES**
The integration of **MES (Manufacturing Execution System)** allowed for better control over the entire production workflow, reducing errors and increasing productivity.
Thanks to the adoption of **Lasertube**, **tube benders**, and **wire benders**, the project achieved a **50% reduction in manpower**, a **52% decrease in production time**, a **26% drop in production costs**, and a **20% reduction in material costs**. This real-life example proves that modern tube and wire processing systems are not just innovative—they’re essential for achieving efficiency, cost savings, and precision in today’s manufacturing environment.
If you're interested in learning more about how these technologies can transform your next project, feel free to reach out for additional information.