Kind of a Big Dill Logo
KIND OF A BIG DILL
Work/Sheet metal // Product design // Laser and brake

Flat sheet in.
Finished product out.

DSPro needed a home for detailing bottles and wash tools: on the bucket, in the bucket and on the wall. Three sheet metal parts, hooks formed instead of welded, their logos cut right into the profile, and drawings any laser shop can quote from.

Request a sheet metal design →See the bottle rack drawing (PDF)
Parts
Bucket bottle rack, Mk2 grit guard, wall bottle rack
Fits
Standard 5 gallon wash buckets
Material
Stainless steel sheet, per drawing
Process
Laser cut, brake formed, no welding
Drawings
ASME Y14.5, PDF and DXF flat patterns
Status
Drawings released
Case study

Three parts, one process

The problem

Detailing bottles and wash tools need a home on the bucket and on the wall. DSPro wanted a bottle rack that hangs on a 5 gallon bucket rim, a grit guard for the bottom of the bucket, and a wall rack, all with their branding cut right into the part.

The approach

Sheet metal from the first sketch. Every part is a flat pattern that gets laser cut and brake formed, with the hooks formed into the part so nothing needs welding. The logos are part of the cut path, not an add-on.

The result

Three parts released as SolidWorks sheet metal models, dimensioned drawings with bend callouts and DXF flat patterns any laser shop can quote from. Assembly animations so the customer could see it on the bucket before anything was cut.

The parts

Three features that do the work

Render of the formed bottle rack with the DSPro and RevAuto logos cut through the sheet
Bucket-rim bottle rack. Hooks formed from the flat pattern, logos in the cut path. CAD render
Render of the laser cut grit guard with radial teardrop slots
Mk2 grit guard. Radial teardrop slots let grit settle below the guard. CAD render
1

Hooks formed, not welded

The bottle rack hangs on the bucket lip with hooks that come out of the flat pattern. One cut, a few bends, no fixtures and no weld cleanup.

2

Branding in the cut path

The DSPro and RevAuto logos are cut through the sheet as part of the profile, so the branding costs nothing extra at the laser and never wears off.

3

Grit guard that drains

Radial teardrop slots let grit fall through and stay below the guard. The pattern is sized for the laser so the slots stay clean and the web stays stiff.

Render of the wall mounted bottle organizer with the DSPro logo
Wall bottle rack, laser cut and formed from the same sheet. CAD render
Process

How it was designed

  1. 01

    Fit to the bucket

    Modeled the rim of a standard 5 gallon wash bucket and designed the hooks around it so the rack sits flat and stays put.

  2. 02

    Sheet metal models

    SolidWorks sheet metal with real bend radii and K-factors so the flat pattern matches what comes off the brake.

  3. 03

    Drawings and DXFs

    Dimensioned drawings to ASME Y14.5 with bend callouts, plus DXF flat patterns for the laser.

  4. 04

    Show it before cutting

    Assembly animations of every part so the customer could sign off on the look and the fit before quoting.

Your product

What this means for your project

Sheet metal products

Designed for the laser and the brake from day one.

Racks, brackets, guards, enclosures and branded accessories. Real bend reliefs, real K-factors, and flat patterns that match what comes off the brake.

Ready to quote

Drawings and DXFs your shop will not call you about.

You get the native CAD, STEP, PDF drawings to ASME Y14.5 and DXF flat patterns. Send them to your laser shop or let me manage the build through shops I know.

Have a product that should be made from flat sheet?

Send me a sketch or a photo of what you are doing today. I reply within 2 business days.

Start a project→