Some parts are easy to make but annoying to assemble

I think this is one of the most underrated things in sheet metal work.

A part can be totally manufacturable and still be frustrating once it reaches actual assembly. Tool access is awkward, the install sequence is tighter than expected, or the part technically fits but not in a way that feels smooth in real use.

This seems to happen a lot with smaller brackets, covers, and internal support parts. Nothing looks wrong in CAD, but in the real product they end up affecting assembly more than expected.

It’s a good reminder that “can be made” and “works well in assembly” are not the same thing.

#sheetmetal# #assembly#