(Grant Hagedorn in Fabricator) Images courtesy of TRUMPF Inc.
Redesigning the bracket eliminates welding and, to varying degrees, eases overall manufacturing.
Simple designs are not always the most cost-effective to manufacture. In the below, Design A shows a seemingly simple bracket. Found throughout manufacturing, the design requires two vertical welds to attach the backplate. Its workflow is as follows: laser, press brake, welding, finishing, and then assembly and shipping.
Design B shows the bracket redesigned with flat tops to ease bending, but the welds are still there. Design C has no welds and requires five bends, three of which are performed simultaneously. Design D also removes the welds and requires only four bends, and the first two again can be formed at the same time. So, in both C and D designs, the brake ram would cycle just three times. It is all a matter of the designer understanding shop floor practices properly.