Added foundational manufacturing section based on Donal's FTX7 manuf guide

docs/design_manufacturing/design/index.md

@@ -1,3 +1,3 @@
-# Design Guides
+# Design
 
 *coming soon...*

docs/design_manufacturing/index.md

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 ## Guides
 
-- [Design Guides](./design/index.md)
-- [Manufacturing Guides](./manufacturing/index.md)
+- [Design](./design/index.md)
+- [Manufacturing](./manufacturing/index.md)

docs/design_manufacturing/manufacturing/index.md

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-# Manufacturing Guides
+# Manufacturing
 
-*coming soon...*
+These pages are the team's manufacturing practices. Use them while designing a part, **not only** after it has been released.
+
+## Guidance
+
+- [General Principles](./manufacturing-guide.md) — process selection, tolerances, fixtures, cost and release checks
+- [Process Guides](./processes/index.md) — sheet metal, weldments and outsourced machining
+- [Workshop Reference](./workshop-reference/index.md) — materials, fasteners and historical costs
+
+The guidance is based on lessons from the FTX7 build. Confirm current workshop capability, supplier availability and competition rules before releasing a part.

docs/design_manufacturing/manufacturing/manufacturing-guide.md

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+# General Manufacturing Principles
+
+Design each part around the way it will be made. Formula Trinity has limited workshop equipment, so decide during design whether a part can be made in-house or must be outsourced.
+
+## Choose the process
+
+Start by asking what the part begins as.
+
+| Starting material and method | Guide |
+| --- | --- |
+| Flat sheet, cut and folded | [Bent Sheet Metal](./processes/sheet-metal-bent.md) |
+| Several sheet or plate pieces, welded | [Welded Sheet Metal](./processes/sheet-metal-welded.md) |
+| Tube, box section, angle or flat bar | [Tube & Box-Section Weldments](./processes/tube-box-weldments.md) |
+| Externally milled solid stock | [CNC Milling](./processes/cnc-milled.md) |
+| Externally turned round stock | [Lathe Parts](./processes/lathe-parts.md) |
+
+Use the appropriate SolidWorks Sheet Metal or Weldments workflow for fabricated parts. Generic solid bodies can hide flat patterns, cut lengths and joint details needed for manufacture.
+
+For mixed assemblies, model each component using its own manufacturing process, then bring the components together in an assembly. Account for weld size, access and interference where relevant.
+
+## Jigs and fixtures
+
+Plan a jig or fixture during design when:
+
+- components must be held accurately during welding
+- a hole pattern must align with a mating part
+- repeatability matters across several parts
+- welding distortion is likely
+- a part is difficult or unsafe to hold
+
+Include dedicated fixtures in the CAD assembly where practical. Printed drill guides, tack-welding locators, marking templates and bend gauges are useful low-cost aids. Keep printed fixtures away from prolonged welding heat.
+
+For a jig printed with a 0.4 mm nozzle, the FTX7 build used approximately 0.4 mm clearance around holes and locating features as a starting point. Test critical features on the actual printer.
+
+## Tolerances
+
+Specify tolerances that the chosen process can achieve.
+
+### In-house fabrication
+
+| Process | FTX7 working guidance |
+| --- | --- |
+| Length cut with an angle grinder | About ±3 mm, approximately ±1–2 mm with a marked line and template |
+| Hole position drilled by hand | About ±3 mm with a printed drill guide, ±5 mm or worse without one |
+| Manually welded assembly | Avoid overall tolerances tighter than about ±3 mm without a suitable fixture |
+
+Make interfaces insensitive to normal fabrication error. Use clear datums, sensible clearance holes, and slots only where adjustment is useful. For example, an 11 mm or slotted hole may suit a non-critical M10 bolt's clearance. Confirm the required edge distance and joint function before use.
+
+### Outsourced machining
+
+Use a sensible general tolerance. The FTX7 working default was **ISO 2768-mK**, unless the drawing deliberately specifies another standard. Apply tighter tolerances only to functional features. Use standard engineering fits where required, particularly for bearing bores and shafts.
+
+For every tight tolerance, identify what fails if the dimension is relaxed. Unnecessary precision increases machining and inspection cost.
+
+## Design for cost
+
+- Use readily available [stock sizes](./workshop-reference/materials-stock.md).
+- Reuse materials and thicknesses across parts.
+- Prefer one folded component over several welded pieces where practical.
+- Choose stock close to the finished component's dimensions to reduce material removal, machining time and waste.
+- Keep outsourced parts compact and machinable in few setups.
+- Remove non-functional machined surfaces and decorative features.
+- Reuse brackets, hole patterns, jigs and templates where appropriate.
+
+## Release check
+
+Before releasing a component, confirm:
+
+- the manufacturing process and responsible manufacturer are known
+- the CAD workflow matches the process
+- the required tools, stock and access are available
+- tolerances are achievable and functionally justified
+- any jig, template or fixture has been designed
+- weld access, weld size and distortion have been considered
+- the part cannot be simplified or combined with another
+- another team member could manufacture it from the drawing
+
+Record lessons from the finished part. They also support the [Design for Manufacture judging topic](../../competition/statics/design/design_for_manufacture.md).

docs/design_manufacturing/manufacturing/processes/cnc-milled.md

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+# CNC Milling
+
+## Drawing and tolerances
+
+- Use ISO 2768-mK as the FTX7 general-tolerance default unless another standard is deliberately chosen.
+- Tighten only functional dimensions.
+- Use standard engineering fits where required, particularly for bearing bores and shafts.
+- State material, finish, deburring and inspection requirements clearly.
+
+## Cost
+
+Prefer geometry that:
+
+- starts from stock close to the finished dimensions
+- needs few setups and tool changes
+- avoids unnecessarily large billets
+- avoids non-functional pocketing and decorative machining
+- limits tightly toleranced features and machined surfaces
+
+Review every tight tolerance before requesting a quotation.

docs/design_manufacturing/manufacturing/processes/index.md

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+# Process Guides
+
+Select the guide that matches how the component will be made:
+
+- [Bent Sheet Metal](./sheet-metal-bent.md)
+- [Welded Sheet Metal](./sheet-metal-welded.md)
+- [Tube & Box-Section Weldments](./tube-box-weldments.md)
+- [CNC Milling](./cnc-milled.md)
+- [Lathe Parts](./lathe-parts.md)
+
+Assemblies may use several processes. Apply the relevant guide to each component rather than forcing the whole assembly into one modelling method.

docs/design_manufacturing/manufacturing/processes/lathe-parts.md

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+# Lathe Parts
+
+*Coming soon...*

docs/design_manufacturing/manufacturing/processes/sheet-metal-bent.md

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+# Bent Sheet Metal
+
+Use this process when a part starts as flat sheet and gains its shape mainly through cutting and folding. Typical parts include guards, brackets, firewalls, enclosures and battery boxes.
+
+If the part can be unfolded flat, it should normally be modelled as a sheet-metal part.
+
+## SolidWorks workflow
+
+Use the Sheet Metal environment from the start. The model should produce:
+
+- a flat pattern for a drawing or DXF export;
+- bend lines and an accurate bend allowance;
+- visible corner relief, flange and bend-interference checks.
+
+Do not create the unfolded shape manually. Set sheet thickness, bend radius and K-factor to match the material and intended tooling. Standard values should be stored in a shared gauge table when they have been confirmed.
+
+## Before release
+
+- Confirm that the available tooling can form every bend.
+- Check flange lengths, bend sequence, corner reliefs and tool access.
+- Confirm the material, thickness, bend radius and K-factor with the manufacturer.
+- Export the flat pattern at 1:1 scale with bend lines clearly identified.
+- Nest externally cut parts onto standard sheets where practical.
+
+The FTX7 reference used 2500 × 1250 mm sheet in 1.5 mm and 3 mm thicknesses. See [Materials & Stock](../workshop-reference/materials-stock.md) before standardising a new design.

docs/design_manufacturing/manufacturing/processes/sheet-metal-welded.md

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+# Welded Sheet Metal
+
+Use this process when a component is made by welding several pieces of sheet or plate. First consider whether one folded part could replace multiple welded pieces.
+
+## CAD setup
+
+- Model each piece as a sheet-metal part with its own flat pattern.
+- Bring the pieces together in an assembly.
+- Account for weld beads, weld access and possible interference.
+- Add locating tabs or other controlled features where they simplify assembly.
+
+## Alignment and distortion
+
+Manually welded assemblies should not normally be expected to hold overall tolerances tighter than approximately ±3 mm without a suitable fixture.
+
+Use a clear datum strategy, appropriate clearance or slotted holes, and a welding fixture where mounting faces or hole patterns must remain aligned. Plan the weld sequence with the manufacturer to limit distortion.
+
+Printed cradles and spacers can help during tack welding. Remove them before prolonged heat exposure or final welding.

docs/design_manufacturing/manufacturing/processes/tube-box-weldments.md

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+# Tube & Box-Section Weldments
+
+Use SolidWorks Weldments for frames and fabricated parts made from tube, box section, angle, flat bar or another standard structural profile.
+
+## SolidWorks workflow
+
+1. Sketch the member centrelines using a controlled 3D sketch or 2D sketches on planes.
+2. Apply **Structural Member** using the stock profile that will be purchased.
+3. Use **Trim/Extend** to create the correct joint and end geometry.
+4. Review the generated cut list and use it as the manufacturing source.
+
+Maintain shared weldment profiles for commonly used stock. Do not measure member lengths from the CAD viewport or recalculate them during manufacture.
+
+## Manual tube-notching template
+
+Where laser-cut tube or a tube notcher is unavailable:
+
+1. Trim the tube against the mating member in the weldment.
+2. Save the tube body as a separate part.
+3. Flatten or convert the tube wall so the notch becomes a 2D curve.
+4. Create a 1:1 drawing with a known reference length, such as 100 mm.
+5. Print with fit-to-page and automatic scaling disabled, then measure the reference length.
+6. Wrap the template around the tube and mark the cut.
+7. Rough-cut outside the line, finish back to it, and test against the mating tube.
+
+The final joint should have no major visible gap before welding.

docs/design_manufacturing/manufacturing/workshop-reference/fasteners.md

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+# Fasteners
+
+Always check the current competition rules before selecting a vehicle fastener. The wiki's FTX7 rules reference defines [critical fasteners and accepted locking methods](../../../ftx7/rules/section-t/10-fasteners.md).
+
+## Baseline selection
+
+- Use property class 8.8 or better where required by the rules.
+- Do not substitute A2 stainless fasteners for class 8.8 without verifying the required strength and joint design.
+- Prefer all-metal prevailing-torque nuts (*k-nuts*) in elevated-temperature areas near the exhaust, engine, brakes or later welding work.
+- Use nyloc nuts only where the applicable rules permit them and the joint remains below the allowed temperature.
+- Use plain nuts for jam-nut arrangements, such as adjustable rod ends, rather than as the default locking method.
+- Ensure the required number of full threads projects beyond a lock nut.
+
+Rule requirements take precedence over workshop preference. Critical joints require an accepted positive locking method, pre-load or thread adhesive alone may not qualify.
+
+## CAD library
+
+*Fastener library?*

docs/design_manufacturing/manufacturing/workshop-reference/index.md

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+# Workshop Reference
+
+Use these pages for information that is normally looked up during design or manufacture:
+
+- [Materials & Stock](./materials-stock.md)
+- [Fasteners](./fasteners.md)
+- [Indicative Costs](./indicative-costs.md)
+
+Confirm availability and prices before release or purchase. Reference values are not a substitute for current supplier quotes.

docs/design_manufacturing/manufacturing/workshop-reference/indicative-costs.md

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+# Indicative Costs
+
+The values below were recorded during the FTX7 build. They are historical comparisons only and are not current quotations. Units, stock lengths, VAT and delivery basis must be confirmed before using them in a budget.
+
+## Material
+
+| Item | Recorded price (€) |
+| --- | ---: |
+| Box section, 20 × 20 × 2 mm | 13.46 |
+| Box section, 30 × 30 × 2 mm | 22.50 |
+| Box section, 40 × 40 × 2 mm | 27.80 |
+| Tube, 33.7 × 3 mm | 30.00 |
+| Semi-bright tube, 19 × 1.5 mm, 6 m | 10.39 |
+| Flat bar, 30 × 3 mm, 4/4.2 m | 6.79 |
+| Mild-steel sheet, 1 mm | 45.25 |
+| Aluminium sheet, 3 mm | 200.00 |
+| Round bar, Ø10 mm, 6 m | 5.77 |
+| Angle, 30 × 30 × 3 mm, 6 m | 18.14 |
+| M10 threaded bar, per metre | 4.40 |
+
+## Consumables and hardware
+
+| Item | Recorded price (€) |
+| --- | ---: |
+| HSS drill bit, 10 mm | 6.00 |
+| HSS drill bit, 11 mm | 8.20 |
+| HSS drill bit, 13 mm | 15.00 |
+| MIG wire, 15 kg × 0.8 mm | 40.00 |
+| M12 × 60 socket-cap fastener | 0.86 |
+| M10 × 50 fastener | 0.75 |
+| Weld-on hinge set | 5.50 |
+
+For competition costing rather than purchasing, use the documented [Cost & Manufacturing process](../../../competition/statics/cost/index.md).

docs/design_manufacturing/manufacturing/workshop-reference/materials-stock.md

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+# Materials & Stock
+
+Design around material that is readily available. The FTX7 guide used Heiton Steel as a reference for commonly available Irish steel stock.
+
+## Standard sheet
+
+The FTX7 baseline for cold-reduced sheet was:
+
+| Sheet size | Thickness |
+| --- | ---: |
+| 2500 × 1250 mm | 1.5 mm |
+| 2500 × 1250 mm | 3 mm |
+
+Use 2500 × 1250 mm as the initial nesting blank for batch cutting, then confirm the actual material and blank size with the supplier.
+
+## Recorded stock range
+
+The following sizes appeared in the FTX7 manufacturing reference. This is a starting point, not a live stock list.
+
+| Form | Recorded sizes (mm) |
+| --- | --- |
+| Box section | 20 × 20 × 2; 30 × 30 × 2; 40 × 40 × 2/2.5/3; 100 × 100 × 3 |
+| Tube | 60.3 × 3; 33.7 × 3; 26.9 × 3 |
+| Semi-bright tube | 19 × 1.5; 25 × 1.5 |
+| Flat bar | 30 × 3; 30 × 6 |
+| Round bar | Ø6; Ø10; Ø12 |
+| Angle | 30 × 30 × 3; 40 × 40 × 3; 40 × 40 × 5 |
+| Threaded bar | M10 |
+
+When adding stock, record the material specification, section size, available length, supplier and date checked.

mkdocs.yml

@@ -94,8 +94,22 @@ nav:
           - Subsystem 2: ftx7/electronics/subsystem-02/index.md
   - Design & Manufacturing:
       - design_manufacturing/index.md
-      - Design Guides: design_manufacturing/design/index.md
-      - Manufacturing Guides: design_manufacturing/manufacturing/index.md
+      - Design: design_manufacturing/design/index.md
+      - Manufacturing:
+          - design_manufacturing/manufacturing/index.md
+          - General Principles: design_manufacturing/manufacturing/manufacturing-guide.md
+          - Process Guides:
+              - design_manufacturing/manufacturing/processes/index.md
+              - Bent Sheet Metal: design_manufacturing/manufacturing/processes/sheet-metal-bent.md
+              - Welded Sheet Metal: design_manufacturing/manufacturing/processes/sheet-metal-welded.md
+              - Tube & Box-Section Weldments: design_manufacturing/manufacturing/processes/tube-box-weldments.md
+              - CNC Milling: design_manufacturing/manufacturing/processes/cnc-milled.md
+              - Lathe Parts: design_manufacturing/manufacturing/processes/lathe-parts.md
+          - Workshop Reference:
+              - design_manufacturing/manufacturing/workshop-reference/index.md
+              - Materials & Stock: design_manufacturing/manufacturing/workshop-reference/materials-stock.md
+              - Fasteners: design_manufacturing/manufacturing/workshop-reference/fasteners.md
+              - Indicative Costs: design_manufacturing/manufacturing/workshop-reference/indicative-costs.md
   - Competition Overview:
       - competition/index.md
       - Static Events: