Key principles.
Self-aligning
Lead-in chamfers (45° × 1mm typical) on mating features. Compensates for robot positioning tolerance. Critical for press fits.
Robot can't flip
Parts must orient correctly when picked. Asymmetric features ensure correct orientation, prevent backwards assembly.
No fasteners
Snap-fit assembly eliminates fastener handling. Engineered snap angles (typically 30-45°) for engagement force.
Vacuum or grip
Flat surface for vacuum picking, or finger-grip features for mechanical grippers. Curved surfaces problematic.
Loose where possible
Robot positioning ±0.1 mm typical. Mating features must accept this tolerance with chamfers and lead-ins.
In carrier
Fasteners pre-installed in carrier strip, or snap-in retainers. Loose fasteners difficult for robots.
FAQ
Manual assembly tolerates orientation errors, complex motions, dexterity. Automated needs unambiguous orientation, simple insertion paths, force-controlled engagement.
Cantilever snap: depth/length ratio 0.1-0.2 for repeated use. Permanent snap: higher engagement force. Consider material flexibility (nylon, ABS good; brittle materials avoid).
Parts must orient consistently when fed. Asymmetric weight distribution helps. Avoid features that catch on each other.
Modern robots use vision for orientation. Reduces orientation features needed. But adds cost — design for vision OR design without vision.
Specialty robots can handle screws and washers. Mass-producing assemblies often use snap-fits or press fits to avoid this complexity.
Automation-friendly design adds upfront engineering cost. Pays back at production volumes (10,000+ assemblies). For low volume, manual assembly often cheaper.
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