Custom Mounting Brackets
Your housing, sensor, manifold, or panel has to sit where the assembly needs it, and the bracket sets that position. K-Display makes L, Z, U, and offset brackets, gusseted and welded brackets, and bracket assemblies, delivered loose, as weldments, or coated with hardware in.
Where the bracket has to land
A bracket’s job is fixed by two things: the hole pattern that fastens it and the flange geometry that sets the component’s position. Both are decided in the flat pattern and in the bends, so the questions that matter come before cutting: how close a hole can sit to a bend, how the two flanges line up through the bend, and whether a gusset or weld is needed to hold position under load.
The mounting flange locates the bracket on the frame, and the component flange locates the part it carries. Those two faces are the datums, and every weld, fastener, and coat of powder is planned to keep them true.
The frame flange fixes the bracket to the machine; the other flange places the housing. The gusset supports that offset while leaving the two mounting faces available for the mating parts.
Brackets we make
- L, angle, and corner brackets
- Single-bend and multi-bend brackets cut and formed from your flat pattern or model, with holes placed to the drawing.
- Z, offset, and U brackets
- Offset, joggle, and channel forms that step a component off a surface or straddle a member.
- Gusseted and welded brackets
- Brackets stiffened with welded gussets or formed return flanges, or joined from several pieces where one bend cannot reach the geometry, including brackets that carry a valve manifold or small housing.
- Brackets with hardware
- Self-clinching nuts, studs, and standoffs pressed in where a flange is too thin to tap, installed to your bill of materials with threads masked through coating.
What decides whether the bracket fits
- Holes near bends
- We set the minimum distance from a bend to a hole or fastener from the tooling that will form the part, and move the feature before cutting when the geometry needs it. A fastener inside a channel or under a return flange is pressed in before forming, because the press cannot reach it afterward.
- Hole positions across a bend
- Holes on two flanges are located to each other through the bend, so bend angle and springback decide whether the pattern meets the mating part. We check hole-to-hole position across the bend on the first formed parts and correct the bend before the rest of the run is formed.
- Flange length and bend radius
- Short flanges and tight radii limit the tooling that can form the part, and on Z and U forms the step height and channel depth depend on tooling clearance. We pick the tooling from the dimensions that cannot move and develop the flat pattern from it.
- Welds, gussets, and flatness
- Welding heat can pull a formed bracket out of square or flat. We plan weld locations, weld sizes, and any bead ground flush around the faces that act as mounting datums.
- Bare faces and hole size after coating
- Powder coat narrows holes and slots and covers every face that is not masked. We mask bonding points, mating faces, and threads, and size holes that take a fastener, a pin, or a mating fit for the finished part.
From flat pattern to finished bracket
Cutting, forming, welding, hardware installation, and coating happen in one shop, so hardware placement and masking are settled with the flat pattern rather than discovered at the end.
Review the bracket against what it carries
Check the model against the component and the structure it mounts to, and settle the bend, hole, and hardware features that affect fit before any part is cut.
Cut, form, and weld
Laser cut the flat pattern, press in any hardware the forming would block, form the flanges on tooling suited to the material and radius, and weld gussets or joints where the design calls for them.
Fit the remaining hardware and finish
Press in the remaining fasteners, mask threads and bare faces, powder coat, and check the finished hole sizes and flange geometry against the drawing.
Check the formed interface
Identify the frame face and the component face on the drawing, then mark the hole positions that connect them. Those are the relationships to check on a formed first part, including any weld or coating that affects how the bracket seats.
The hole patterns on both flanges must meet their mating parts after forming. Bend angle and flange position connect those patterns, so checking the flat holes alone cannot establish the finished fit.
Start with what you have
A model, a dimensioned sketch, or a legacy part is enough to start. We develop the flat pattern from it.
- Model or drawing
- STEP or DXF plus a PDF with the critical dimensions marked, and the material grade, temper, and thickness.
- What it carries and mounts to
- The component, the frame or panel, fastener sizes, and which holes locate the bracket and which are clearance.
- Hardware and finish
- Fastener part numbers and whether you supply them, coating color reference and texture, faces that stay bare, and whether hole sizes are pre-coat or finished.
- Quantities and delivery
- Order quantity, delivery date, any inspection requirements, and whether you want loose parts, hardware installed, or coated parts.