Design Guidelines
Best practices and recommendations for designing optimal structural solutions using AngleLock technology.
Design Philosophy
Purpose-Driven
Design for your actual requirements, not hypothetical future needs. Start simple and expand as needed.
Modular Thinking
Leverage modularity. Design in subassemblies that can be built, tested, and modified independently.
Performance First
Prioritize structural performance. Rigidity and precision are easier to maintain than to add later.
Structural Design Principles
Minimize Unsupported Spans
Deflection increases exponentially with span length. Adding intermediate supports dramatically improves stiffness with minimal material.
48" shelf with center support: 4x stiffer than single 48" span
Using larger extrusions to span gaps that could be supported
Optimize Extrusion Orientation
Position extrusions with the strong axis perpendicular to the primary load. Rectangular profiles have different stiffness in each direction.
40x80mm extrusion with 80mm dimension vertical for shelving
Using the weak axis for primary loading direction
Create Triangulated Structures
Triangulation prevents racking and distributes loads efficiently. Add diagonal bracing for tall or wide structures.
Add diagonal braces to tall structures > 6 feet in any dimension
Relying only on corner connections for lateral stability
Distribute Loads Evenly
Design load paths to distribute forces across multiple structural members. Avoid concentrating loads at single points.
Use spreader plates under heavy equipment to distribute loads
Mounting heavy equipment at a single extrusion location
Plan for Leveling and Alignment
Include leveling feet or adjustment mechanisms from the start. It's much easier than shimming later.
Use adjustable leveling feet at all base corners (minimum 4 points)
Assuming floor is perfectly level (it never is)
Application-Specific Guidelines
Machine Bases & Equipment Supports
- Size for 150% of equipment weight
Account for dynamic loads and future additions
- Consider vibration isolation
Add vibration pads or isolation mounts for rotating equipment
- Provide access for maintenance
Leave clearance around equipment for service and inspection
- Include cable/hose routing
Plan internal channels for power, air, and coolant lines
Workstations & Work Platforms
- Design for ergonomics
Work surface height: 28-42" adjustable or 36" fixed for standing work
- Size work surface appropriately
Minimum 24" depth x 48" width for general assembly work
- Plan for accessories
Include provisions for lighting, monitors, tool storage, power strips
- Allow for future expansion
Design base structure larger than immediate needs for adding shelves, overhead structures
Safety Enclosures & Guarding
- Meet safety standards
Consult OSHA 1910.212 and ANSI B11 standards for guard height and mesh size
- Maximize visibility
Use polycarbonate or wire mesh panels to allow process monitoring
- Design for access
Include doors or removable panels large enough for equipment service
- Consider sound attenuation
Add sound-dampening panels for noisy equipment
Design Optimization Tips
Material Efficiency
- • Use standard extrusion lengths (8', 10', 12', 16', 20') to minimize waste
- • Design dimensions in multiples of extrusion lengths when possible
- • Consider using smaller profiles with closer spacing vs. larger profiles with longer spans
- • Reuse cut-offs from longer pieces for shorter structural elements
Assembly Efficiency
- • Design structures that can be assembled horizontally then stood up
- • Use symmetry to reduce the number of unique components
- • Minimize bracket types - standardize connections where possible
- • Plan assembly sequence - avoid creating inaccessible connections
Performance Optimization
- • Add cross-bracing before increasing extrusion sizes
- • Use gussets at corners for heavy-load applications
- • Consider composite beam sections (multiple extrusions joined)
- • Verify deflection limits for precision applications (L/360 typical)
Future-Proofing
- • Design base structure oversized to allow for additions
- • Include mounting slots for future accessories
- • Document as-built dimensions for future modifications
- • Keep spare brackets and fasteners for field changes
Common Design Mistakes
Under-sizing for deflection
Consequence: Structure may be strong enough but deflects excessively under load
Solution: Check deflection calculations, not just load capacity. Add supports or use larger extrusions.
Ignoring lateral loads
Consequence: Structure racks or tips under side loads or impacts
Solution: Add diagonal bracing or design base wider than top to lower center of gravity.
Poor weight distribution
Consequence: Uneven loading causes twisting and premature failure
Solution: Position heavy equipment over load-bearing members, not spanning between them.
Inadequate leveling provisions
Consequence: Structure rocks or requires extensive shimming during installation
Solution: Include adjustable feet at minimum 4 corners, more for larger structures.
No access for maintenance
Consequence: Equipment servicing requires partial disassembly of structure
Solution: Plan removable panels or doors in high-access areas during design phase.