From compact robotic cells to fully integrated production lines, we’re entering a new era of automation. This requires uncovering ways to build smarter, faster, and more flexible and reliable systems that can adapt easily to changes.
To prepare, let’s start at the beginning. This article highlights basic foundational machine design elements: frames, guides, drives, and controls.
1. Designing Frames
There are different types of frame materials. Some of the most common materials include sheet metal, welded frames, wood, and aluminum extrusions.
Aluminum extrusions are a common choice for machine design since they are lightweight, cost-effective, corrosion resistant, and provide flexibility. Not to mention, they are also aesthetically-pleasing.
Here are few things to consider if you’re leaning towards aluminum for your frame design.
- Aluminum is weaker than steel.
- Aluminum uses bolt and screw type of connections, which are not as permanent as welding.
- Extrusions are not as rigid compared to other common types like steel, but there are extrusion types that offer higher rigidity.
You also want to consider scalability. Whether you’re planning to increase throughput, integrate new automation technology, or add vision inspection, the frame should accommodate these updates without requiring a total redesign. Using standardized, configurable frame elements (with precise cut lengths and machining options available on demand) makes scaling up or retooling a straightforward process.
Common Extrusion Types
Aluminum extrusions come in a wide variety of shapes and sizes, as well as anodizing options, with the most common being a standard square shape.
Here is a quick comparison of aluminum extrusions types:
| Aluminum Extrusion Types | Key Characteristics | Best For / Typical Application | MISUMI Product Example (By Part Number) |
|---|---|---|---|
| Standard Aluminum Extrusion | Balanced strength and weight; versatile slot configurations | General automation frames, enclosures, workstations | HFS5-2020 |
| High-Rigidity Extrusion | Thicker walls and reinforced cross-sections for high load capacity | Machine bases, gantry systems, heavy-duty automation | GFS8-4040 |
| Lightweight Extrusion | Reduced wall thickness for lower mass while maintaining accuracy | Portable systems, adjustable guards, test setups | HFSL6-3030 |
| Bend Slot / Parallel Chamfer Type | Curved or multi-axis profiles with aligned or flexible slot orientations; allow creative or ergonomic frame layouts | Rounded guarding, ergonomic cells, and modular equipment needing flexible mounting | HFSP5-2020 |
| Mixed Slot / Small Corners Type | Combines varied slot orientations with compact geometry for space efficiency and flexible mounting | Reconfigurable workcells, compact equipment, and tight-space automation frames | HFSV6-3030 |
There are also different types of coating options:
| Surface Treatment | Key Characteristics | Best For / Typical Application |
|---|---|---|
| Clear Anodized | Standard corrosion resistance; professional appearance | Cleanroom, lab automation, general environments |
| Black Anodized | Low reflectivity and high surface hardness | Vision inspection systems, optical setups, premium equipment |
| Yellow (Baked-On Finish) | Visual safety indication, easy identification of guarded areas | Machine guarding, operator-accessible zones |
Design Faster with FRAMES
FRAMES, an aluminum extrusion design software, makes the design or reconfiguration process easy with drag-and-drop capabilities and joints and brackets automatically added as you design. You can download the free software here.
Aluminum Extrusion Accessories
The basic assembly of a frame is simple: the extrusion, bracket, and nuts and bolts.
But there are several accessories you can use to elevate your frame design, such as:
2. Choosing the Right Guide
The right guides will achieve smooth, accurate motion that your design requires. Components like linear bearings, shafts, rails, and bushings ensure other parts move along a defined path with little friction.
For high-precision applications, even a fraction of a millimeter of misalignment can cascade into product defects or premature wear.
Here are some things to consider when choosing a guide system:
- Maintains parallelism and straightness across long travel distances.
- Minimizes vibration, backlash, and drift.
- Reduces maintenance needs and extends component life.
- Supports heavier loads without compromising accuracy.
The right guide depends on the application’s load, speed, environment, and accuracy requirements. Let’s take a look at the most common guides found in industrial automation applications.
| Guide Type | Use Case | Common Applications |
Linear Ball Bearings | Linear ball bearings support the load of a carriage during single-axis movement and provide a low friction. Linear shafts for linear ball bearings are available in different lengths, materials, and tolerances. | CNC machines, 3D printers, imaging and surgical robots, and packaging and printing equipment. |
Bushings | Bushings help to reduce friction during motion and constrain motion to one axis. They help to move parts smoothly and easily. They are used in a wide of range of applications that have a light/moderate load and require low accuracy. They are also low in cost. | Fitness equipment, packaging machinery, 3D printers, and assembly jigs. |
Linear Guides  | Linear guides are a bearing that uses recirculating balls or rollers to reduce friction and constrain motion to one axis or one direction. They are ideal for applications that require moving parts smoothly and easily when they have moderate/high loads and are high rigidity. | CNC machines, microscopes, water jets, X-ray machines, robot transfer units, automotive assembly fixtures, 3D printers, and packaging machines. |
Cam Followers | Cam followers minimize friction via rolling motion, making them ideal for supporting loads or guiding motion along a defined path. | Packaging machines, medical equipment, pick and place machines, clamps and grippers, and bottling machines. |
Rotary Bearings | Ball and roller bearings consist of hardened steel rolling elements positioned between an inner and outer race, enabling high-speed, low-friction rotation. Proper implementation improves machine efficiency and minimizes noise and heat. | Automotive, robotics,. production machines, conveyors, and medical equipment. |
Rollers | Conveyor rollers are used in conveyor systems to facilitate the movement of goods and materials. They are designed to reduce friction and provide smooth transportation, making them essential components in manufacturing and logistics. | Assembly lines, workstations, warehousing, and packaging lines. |
Spline Shafts | Spline shafts have ridges or teeth that mesh with grooves in a mating part, such as a gear or hub, to transmit torque while maintaining alignment. | Paper manufacturing, robotic arms, pick-and-place machines, CNC machines, and automated packaging equipment. |
Rod End Bearings | Rod end bearings allow for rotational movement between different parts. They consist of a spherical outer surface that fits into a housing, providing a pivot point. | Robotics, material handling and equipment, positioning systems, and packaging machines. |
MISUMI offers a variety of linear guides along with several grease options (high temp, clean room, and self lubricating). With MISUMI, you can specify stroke length, preload, surface treatment, and material to get the right part needed, rather than going fully custom.
Integrating Guides with the Frame
When integrating guides with the frame, here are some tips:
- Design rigid mounting points and minimize joint interfaces.
- Use machined reference surfaces or locating features in your frame.
- Ensure thermal and mechanical loads are evenly distributed across the guide.
3. Driving Efficiency with Smart Actuation
Whether electric, pneumatic, hydraulic, or manual — drives convert power into controlled, repeatable motion. Selecting the right actuation solution can boost efficiency, reduce energy consumption, and extend machine life.
On the other hand, the wrong drive can cause vibration, heat buildup, excessive wear, and even premature failure.
Common Drive Methods
Here is an overview of some of the different drive methods, including product examples:
| Drive Type | Use Case | Common Applications |
Ball Screws | Ball screws converts rotary motion to linear motion, offers precision movement for various applications, and are designed to minimize friction and wear. | CNC machines, X-ray machines, DNA sequences, 3D printers, packaging machines, airplanes, and car power steering. |
Timing Belts & Pulleys | Timing belts transmit torque to other components or convert rotary motion into linear motion. They are low cost and suitable for a wide range of loads and accuracy requirements. | Fitness equipment, packaging machinery, 3D printers, conveyors, low-cost CNC machines, and medical lab automation. |
Chain & Sprockets | Chains are used to transmit torque generated by a power source to other machinery or parts and are usually used in combination with geared machinery called sprockets. | Power transmission, material handling systems, automotive, assembly lines, and packaging equipment. |
Gears | Gears are offered in a variety of types, including spur, helical, bevel, worm, and rack and pinion. They are often categorized by their shaft orientation (parallel, intersecting, or non-parallel and non-intersecting), tooth type (straight, angled, or curved), or function. | Conveyor systems, robotics, medical equipment, assembly lines, material handling, aerospace, and automotive. |
Hydraulic Cylinders | Hydraulic cylinders convert fluid into linear motion and are used to push, pull, lift, or press. | Hydraulic presses, material handling, and aerospace. |
Air/Pneumatic Cylinders | Air cylinders convert compressed air into linear motion by using air pressure to move a piston inside a barrel, which then moves a connected rod that can be used to clamp, lift or push. | Assembly lines, packaging, sorting and handling, aerospace, medical, and automotive. |
Motorized Rotary Stages | Motorized rotary stages are precision devices that enable rotational movement in a controlled and automated manner. These stages provide accurate positioning and smooth rotation, making them vital for tasks that require precise alignment and orientation. | Robotics, microscopy, and optical measurement. |
Manual Drives | Manual drives can be designed using handles, wheels, and/or levers, such as door and drawer handles. | Storage solutions, medical and lab equipment, electronic enclosures, motion controls, material handling, and safety mechanisms. |
Integrating Drives with Guides and Frames
Proper integration between the drive system, guides, and frame is essential. Here are some tips:
- Mount motors and actuators directly to rigid, vibration-resistant surfaces.
- Align actuators with guides to prevent side loads that increase wear.
- Use modular drive mounts to simplify maintenance and future upgrades.
4. Choosing Controls that Integrate and Offer Scalability
Controls connect mechanics and intelligence and dictates how smoothly your machine moves, responds to feedback, and adapts to changing conditions. For best performance, select controls that integrate seamlessly with your drives and mechanical systems, match the precision requirements of your application, and provide flexibility for future upgrades.
Even the most sophisticated controller is ineffective if it cannot communicate with your drives, sensors, and actuators. Proper integration ensures:
- Reliable and repeatable motion.
- Simplified commissioning and reduced debugging time.
- Lower risk of errors during maintenance or upgrades.
Most automated machinery or systems nowadays have some sort of electrical interface that allows the operator to interact with the operation and control of the machine. Human-Machine Interfaces (HMIs) and Programable Logic Controllers (PLCs) are two key components that can be used individually but are often used together to operate and monitor machinery and processes.
Overview of PLC
A PLC is a specialized computer system used for industrial automation, controlling machines and entire production lines by receiving inputs, applying programmed logic, and driving outputs.
It operates without conventional computer peripherals (like display or keyboard) and serves to integrate mechanical and electrical systems seamlessly.
PLCs come in a variety of sizes and with different capabilities, but they all include the following five components:
| PLC Component | Description | Product Example |
|---|---|---|
| Central Processing Unit (CPU) | The “brain” of the PLC where software logic resides; it processes inputs and determines outputs. |  Mitsubishi Electric Automation MELSEC iQ-F FX5U Series Sequencer CPU |
| Input Module | Interfaces with field sensors (digital or analog) to capture signals from the outside world. |  Mitsubishi Electric Automation MELSEC-Q Series Input Unit |
| Output Module | Drives downstream devices (motors, lights, drives etc.) based on CPU decisions. |  Mitsubishi Electric Automation MELSEC-Q Output Unit |
| Power Supply | Converts incoming line voltage (AC) to the required DC voltage (often 24 V) and often provides battery backup. |  Mitsubishi Electric Automation MELSEC-Q Series Power Supply Unit |
| Programming Unit (HMI) | Allow operators to monitor/control processes, view KPIs, machine health etc. |  Mitsubishi Electric Automation HMI Display, GOT2000 Series, GT27 |
To integrate a scalable PLC, start by understanding the specific application requirements and what tasks it will need to operate, your application’s environmental conditions, and ensure that the PLC you choose supports additional modules or functions.
Overview of HMIs
HMIs allow users to monitor relevant data and control the connected machines. Using programmable software, these devices can be configured to your specific needs.
While the term HMI can technically apply to any device that relays information to a human operator, most HMIs share several defining features including a screen, some form of input device, and programmable software.
It is important to keep in mind that HMIs are an extension of a PLC system, and that any data being processed by the PLC can be sent in some form directly to the HMI.
For example, say you wanted to implement an HMI for a robot that takes packages from a conveyor belt and places them onto pallets. You could program the HMI to display an overlay of the pallets, indicating how many packages are on each one. You could also add a camera feed from the robot arm POV to see what is being taken off the conveyor belt.
Machine design isn’t just about parts …
… it’s about how parts work together.
Focus on integration, modularity, and adaptability, and you’ll succeed in building machines that perform better today and evolve seamlessly tomorrow.
With the right combination of frames, guides, drives, and controls, you can turn complex machines into smart, efficient, and future-ready solutions.
Struggling to find the right parts? MISUMI offers 80 sextillion part configurations and over 3,000 renowned mechanical and electrical brands.
