How would you make this part?

[kiramunch@sympa]

I need to make this part in quantity and economically out of a home shop enviornment. The material is .063 6061 aluminum. The slots and the holes are water jet cut and right now I am rolling the cuff portion and welding to tubing stubs. I would like to go to a 1 piece design to eliminate the welding as like the one in the picture. I do not have the money or room for a large stamping machine and dont mind if the solution is a slow one-at-a time pace with basic tools/machinery. Can anyone provide any suggestions? Thank you

[MrWild]

How much are you allowing your

[MrWild]

How much are you allowing yourself to make a die and tooling? You could make a die that is closed with a hydraulic ram and opened by springs. To automate the ram a bit you could use a motorized pump instead of hand pump. A big question is, how many do you need to make? You lose so much time to rolling and welding/cutting, that you might job out the stamping part and be ahead.

[kiramunch@sympa]

This item would be a constantly produced piece. We would probably make at least 100 at a time and just make more as the inventory got down. We dont mind starting out with a hydraulic jack type of affair and eventually motorizing. We have jigs for welding right now but it's not how we want to do it long term. A tool and die shop is a good suggestion.