Sample capability project. This is an illustrative example of the type of work AGX Engineering delivers — not a confirmed client project. It is presented to demonstrate scope, process, and deliverables.
Laser-Cut Bracket Set
DXF flat patterns and fabrication drawings for a set of mild steel mounting brackets
Project Overview
About This Engagement
- Client
- Sample Capability Project
- Location
- Australia
- Category
- DXF & Laser/Waterjet Files
- Completed
- Example
This sample project illustrates AGX Engineering's approach to producing DXF flat patterns for a multi-part bracket set destined for laser cutting. Bracket sets of this type are commonly required for equipment mounting, panel attachment, and structural connections across fabrication, agricultural, and industrial equipment manufacturing.
Each bracket in the set is modelled parametrically in SolidWorks with the correct material thickness, bend radius, and K-factor applied before unfolding. The resulting flat patterns are exported as clean, layer-structured DXF files with no open polylines or duplicate geometry — ready for direct machine input without operator correction.
The Challenge
Problem and Requirements
Laser-cut brackets often come from 2D sketches or verbal descriptions, making it difficult for operators to produce accurate flat patterns without manual calculation of bend allowances. Incorrect flat patterns lead to scrap material and repeat cutting runs.
This example brief covered a twelve-bracket set with three distinct part types, two different material thicknesses (3 mm and 5 mm mild steel), and a range of slot, hole, and notch features. The client required DXF files alongside PDF check prints for operator verification before nesting.
Our Approach
Engineering Solution
AGX Engineering modelled each bracket in SolidWorks using the sheet metal environment, with K-factors and bend allowances set for the specified material and bend radius. Flat patterns were unfolded in SolidWorks and exported as DXF files in AutoCAD 2010 format, with cut profiles on a dedicated LASER-CUT layer and internal features on a separate ETCH layer — matching the cutting operator's layer naming convention.
PDF check prints were generated alongside each DXF file, allowing the operator to verify geometry and dimensions before nesting. A part schedule listing part number, material, thickness, quantity, and flat size was included to allow efficient nesting and material allocation.
What Was Produced
Deliverables
All documentation was produced to a professional standard so the client's supply chain could work from it directly.
- SolidWorks sheet metal part models (one per bracket type)
- DXF flat pattern files — layer-structured for laser cutting
- Bend allowance documentation (K-factor, material, bend radius)
- PDF check prints alongside each DXF file
- Part schedule with part number, material, thickness, and quantity
Technology
Software and Tools Used
The engineering tools and software platforms used to design, analyse, and document this project.
- SolidWorksCAD
- AutoCADDrafting
Related Work
Services Used on This Project
Explore the engineering disciplines that contributed to this engagement.
DXF & Laser/Waterjet Files
Layer-structured DXF flat patterns for laser, waterjet, and plasma cutting.
3D CAD Modelling
Parametric sheet metal modelling with correct bend allowances for flat pattern production.
Manufacturing & Fabrication Drawings
Fabrication drawings to accompany DXF flat patterns for press brake work.
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