Many engineers make the common mistake of using T-slot aluminum extrusions indiscriminately across their production lines. Here’s how to avoid overbuilding, overspending, and creating unnecessarily robust structures.
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This guide covers the following topics:
Determine your structure's loading capacity using our CAPACITY CHARGE CALCULATOR.
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Understanding the Unique Advantages of Each System
These modular systems are not direct competitors since each has its unique strengths, suited for different applications. T-slot aluminum constructions are preferable for production systems involving robotics and automation due to their sturdiness and precision. On the other hand, the pipe and joints system aligns perfectly with Lean Manufacturing principles, being easy to assemble, customize, and more cost-effective.
Benefits of Pipes and Joints Systems
More affordable
Quick assembly
Simple design and assembly
Convenient online ordering
Easy testing, improvement, and adaptation for lean purposes
Advantages of T-slot Aluminum Extrusions
Higher load capacity
Durable structures capable of rapid and repetitive movements
Sleek, modern design
Greater precision
Ideal for jigs, fixtures, and robotics
Integration options for robotics and automation systems
Choosing the Right Modular System for Your Needs
When selecting a modular system for your production line, consider factors such as floor efficiency, employee safety and ergonomics, and the ability to adapt your production blueprint over time. T-slot aluminum profiles and tubular systems each offer distinct solutions. The decision should be based on the unique characteristics and requirements of your production context.
Defining Your Structure's Purpose
T-slot aluminum constructions are the obvious choice for applications involving robotics and automation due to their stability and precision. These constructions can support a variety of high-precision tasks such as:
The Precision Factor
When it comes to precision, T-slot aluminum systems stand out. They offer robust connections with tight tolerances. On the other hand, the leave extra space in pipe and joints systems can be helpful in accommodating minor errors but compromises precision.
Best Applications for Pipe and Joint Structures
Pipes and joints systems are better suited for material handling systems that do not require the precision of aluminum extrusions, including:
Examples of Specific Applications
Flow racks
Return lines for empty containers
Supermarket racks to have stock nearby
L-shaped flow racks for part proximity
Gravity-fed workstations to free up floor space
For more information on flow racks, check out this article on the most common types of modular gravity flow racks and how they can increase production line efficiency.
Racks
Adaptable racks
Shelving with added value
WIP racks to reduce defects
Storage racks intended as poka-yoke
For more information on racks, check out this guide on the most popular modular industrial racks and shelving systems.
Workstations and Workbenches
U-Cell stations improve lead time
Ergonomic stand-up stations and work centers
Personalized adjustable working tables
ESD workstations to reduce defects
For more information on workstations and workbenches, check out this guide on different types of custom-made industrial workstations & workbenches.
Modular Boards
Point-of-use or shadow boards
Rotating cube and 8-faced boards
Meeting space boards
1, 2, 3, or 4 sided boards
For more information on boards, check out these types of modular boards.
Carts
Kitting carts
Tuggable carts
WIP carts
Warehouse picking carts
Truck carts
For more information on carts, check out this guide on popular types of carts for industrial material handling.
Evaluate the Required Loading Capacity
The most robust structures in pipe and joint systems can support up to 2000 pounds, but they won't be as strong as aluminum extursions because of thickness and diameter constraints. Variations in pipe thickness provide adaptability, but even the sturdiest Flexpipe structures may fall short in comparison to T-slot aluminum profile structures such as those made from 6063-T5 extrusions, which offer substantial load-bearing capabilities.
Determine your structure's loading capacity using our CAPACITY CHARGE CALCULATOR.
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Will Your Structure Evolve Over Time?
Pipes and fittings systems offer lower costs and simplicity, enabling easier testing and quicker modifications, making them ideal for continuous improvement processes. However, the higher cost of aluminum extrusion profiles makes such testing more expensive and less flexible.
The Ease of Adaptation
Flexpipe systems, due to their Lean Manufacturing principles, are easily adaptable to changing production needs. Changes can be quickly implemented and tested, fostering a culture of ongoing improvement. T-slot aluminum frames, while more complex to modify, offer greater possibilities for integrating robotics and automation systems.
Budget Considerations
Generally, aluminum systems are about 30% more expensive than Flexpipe. The cost of the material plays a significant role when designing numerous workstations and production systems. In logistic applications requiring features like push-carts and flow racks, the affordability and flexibility of pipe and joint systems offer an advantage over T-slot aluminum extrusion profiles.
Is Aesthetics Important?
For those prioritizing sleek, modern looks, T-slot aluminum profiles are often preferred. Though colored aluminum extrusions are available, the most common finishes are clear or anodized blue. Flexpipe systems offer a wide range of colors, making them suitable for color-coding production environments or bringing a lighter atmosphere to workspace aesthetics. Stainless steel tubes with chrome-plated joints provide a clean, streamlined look.
To better visualize what a pipe and joint structure looks like, check out our photo gallery featuring structures assembled by the Flexpipe team.
Takeaway
Both T-slot aluminum extrusions and pipe and joint systems provide customized, efficient solutions, each suited for different production contexts. T-slot aluminum profiles are better suited for robotics or automation-related structures, while pipes and fittings systems are ideal for flow racks, workstations, modular boards, or carts.
Temie Fessa, a project manager for Flexpipe with over ten years of field experience, notes that many clients use both systems for different contexts. Engineers familiar with aluminum extrusions often continue using them out of habit unless prompted to explore more cost-effective solutions. Discovering the ease and affordability of tubular systems often leads companies to integrate these systems extensively, especially for non-heavy-duty or precision applications.
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Can a long-standing product be improved upon? It depends on the application.
Traditionally, modular aluminum systems have been synonymous with T-slot extruded profiles. But there's a growing interest in an alternative system known as AngleLock, designed to address issues of precision, reliability, and joint strength commonly associated with T-slot systems.
Key Differences Between T-Slot Aluminum and AngleLock Alternatives
Let's explore the fundamental differences between traditional T-slot profiles and this emerging alternative. First, here’s a recap of T-slot characteristics:
Features of Traditional T-Slot Systems
T-slot systems are widely used and well-known. Their fasteners align perpendicularly to the profile, but they rely heavily on friction, often causing alignment issues.
Created via extrusion processes
Utilizes a modular design with various components
Widely recognized solution
Introducing the AngleLock Alternative
Designed to overcome the inherent limitations of T-slot systems, AngleLock uses a nearly identical manufacturing process but offers unique structural support. Its self-aligning brackets and angled bolts eliminate pivot points, allowing for a mechanical lock that offers five planes of anchoring.
More manufacturers are considering AngleLock, particularly because of its robust structural support and reliability in dynamic applications.
Comparative Review: T-Slot and AngleLock in Six Project Criteria
We’ll assess both systems based on the following criteria:
- Strength
- Precision
- Versatility
- Service life
- Cost
- Lead time
1. Strength Considerations
Both systems aim to marry strength with lightweight design. However, the T-slot's friction-based holding mechanism makes it less reliable for maintaining alignment and strength compared to AngleLock’s mechanical lock.
Winner: AngleLock in most settings
2. Assessing Precision
In static environments, T-slot systems work reasonably well but struggle in dynamic settings due to potential alignment issues. AngleLock’s design offers a precise mechanical bond, maintaining alignment even under stress.
Winner: AngleLock for dynamic applications
3. Versatility in Applications
While T-slot systems offer a wider variety of profiles and compatibility with various components, AngleLock provides a unique joint strength and can be disassembled for reuse.
Winner: Draw
4. Service Life and Maintenance
T-slot systems require regular maintenance to prevent misalignment and loosening, which can compromise safety. In contrast, AngleLock’s mechanically bonded assemblies require minimal maintenance and have a longer service life.
Winner: AngleLock by a significant margin
5. Cost Analysis
While T-slot systems might be more cost-effective initially, the long-term expenses due to frequent maintenance and potential replacements often outweigh the initial savings. AngleLock offers better lifetime value despite potentially higher upfront costs.
Winner: T-slot for short-term projects; AngleLock for long-term applications
6. Lead Time Considerations
T-slot systems benefit from widespread availability, ensuring quick lead times. However, AngleLock’s simplified assembly and self-aligning nature speed up the overall setup process.
Winner: T-Slots for immediate needs, with an asterisk for complex assemblies
Final Verdict: T-Slot vs. AngleLock
Aluminum structural framing systems are critical to the success of your manufacturing processes. Here’s when to use each system:
Stick with T-slot systems if: You have low-intensity applications, a limited budget, or require a broad range of components.
Consider AngleLock if: You need high tolerance, strong, reliable structures, and are focused on long-term success and innovation.
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