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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 reduced time and material waste in the construction of a bicycle shelter. This case study highlights how **contractors** and **designers** can benefit from modern tube and wire processing systems to enhance the efficiency of fabricating structures and tubular frames.
The project showcases how integrating these technologies can streamline the entire production process, from initial design to final assembly. Below are the key steps that contributed to the optimization of the frame's design and manufacturing:
1. **Project description and design features of the bike shelter**
The shelter is an outdoor structure designed for bicycle parking, featuring tubes of various diameters, metal wire, and sheet metal. Traditionally, such projects would take 6–8 weeks using conventional methods, with two days dedicated solely to component assembly. This lengthy process often relied on numerous **welding jigs**, requiring skilled labor and careful placement of parts. However, due to the complexity of the design, precision in the final assembly remained limited.
2. **Simplifying connections through the use of joints and bend cuts**
By incorporating **joints, pass-through holes, hooks, and cut-and-bend parts**, the construction of the frame became more straightforward. These connections ensure precise positioning of components, making assembly and welding easier and improving overall accuracy. **ArTube**, the Lasertube programming software, played a crucial role by offering a library of ready-to-use joints and connections that could be applied parametrically within CAD models.
3. **Replacement of complex sheet metal elements with simpler tubular ones**
Initially, support elements were made from cut, bent, and welded sheet metal, requiring three different machines: a **sheet metal cutting system**, a **press brake**, and a **welding machine**. With **Lasertube technology**, these elements were replaced by a single rectangular-section tube that was **laser-cut and bent**. This not only simplified the manufacturing process but also eliminated the need for multiple machines, reducing both time and cost.
4. **Laser cutting and bending to reduce material consumption**
Slots and teeth were used in the transverse support tube to accommodate bent tubes and rods that hold the bicycles. This approach not only simplified assembly but also saved material by shortening the length of the rods. Additionally, **All-In-One technology** helped minimize waste by compensating for deformation during bending, allowing for accurate laser-cut and bent tube parts right from the start.
The result of this re-engineering was impressive: a **50% reduction in manpower**, a **52% decrease in production time**, a **26% drop in production costs**, and a **20% reduction in material costs**. These improvements highlight the power of modern tube and wire processing systems in transforming traditional manufacturing approaches.
By leveraging **Lasertube**, **tube benders**, and **wire benders**, manufacturers can achieve greater efficiency, precision, and cost savings—making it a smart choice for any project involving tubular or wire-based structures.
**Ask for more information** to discover how these technologies can transform your next project.