MANUFACTURING TIPS

When designing a part with threaded holes attempt to make other non-critical holes use the same size as the tap drill.

Consider “Clinching” as opposed to Spot Welding, Riveting and Adhesives.  Clinching is a non-heat, non-pierce operation. Joints are watertight, dissimilar metals can be joined and clinching can be done on pre-painted parts.

 

Always attempt to use connectors with “built-in” strain relief.  If not available for your application consider over-molding first and last heat shrink. In addition design an “S” bend into all harness joints to provide strain relief.  The number one failure mode of cable harness is wire to terminal connection. Pull force, vibration and bending all can damage these joints. Worst still these are typical intermittent failures which are extremely hard and expensive to diagnosis.