Case study · Aluminum extrusion

Extruded solar roof mounts, simulated first

Custom aluminum profiles for rooftop solar: tile hooks and side clamps. Each one was validated with FEA before the die was cut, then prototyped and installed on real roofs.

Client
Nazda — solar mounting line
Scope
Profile design · FEA · assembly · installation
Tools
SolidWorks · stress simulation
Result
Profiles in the product line

An extrusion die is a commitment: once it is cut, every change costs money. We simulated each hook and clamp under load first and adjusted the sections until the stress was where we wanted it.

The profiles were then prototyped, assembled with the panels and installed on residential tile roofs.

FEA stress plot of a tile roof hook
Hook · FEA
FEA stress plot of a side clamp
Clamp · FEA
Render of the hook holding a solar panel on a tile roof
Assembly render
Installed aluminum hook under a roof tile
Installed
Finished residential solar installation
On the roof
Display board with the extruded aluminum profiles
Profile family

Services used

  • 01

    DFM review

    Draft, walls, gates and parting line checked, plus fill/warp simulation and a written report.

    $750 – 1,25048 hours

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