Aerospace Sheet Metal Enclosure — Nutplate Assembly & MIL-STD

Challenge: Design lightweight aluminum enclosure for critical flight electronics — optimized for structural integrity, vibration damping, and field maintenance access. What I did: - Sheet metal modeling using SolidWorks Sheet Metal module - Nutplate assembly integration (NAS1791, NAS1792 series) - Rivet pattern layout per MIL-STD specifications - Tolerance stack-up analysis for fastener and flange alignment - DFM applied to simplify tooling and forming process - Material: AL 2024-T3 with aerospace surface treatment Result: Passed structural & vibration testing · Zero NCRs on first article inspection · Flight-readiness confirmed Tools: SolidWorks Sheet Metal · GD&T ASME Y14.5 · DFMEA · MIL-STD · DFM · Tolerance Stack-up