Slots and Tabs

Slot and tab construction involves interlocking parts like a 3D puzzle. Tabs on one piece fit into slots on another, aligning the parts automatically. When glued, bolted, or clamped together, this method creates fast, rigid assemblies without complex tools.

How It Works

• CAD parts are designed with matching cutouts and tabs.

• Cut from flat sheet stock (metal, polycarb, plywood).

• Tabs insert into slots and are fastened with screws, rivets, glue, or welding.

Pros

• Fast Assembly: Self-aligning joints reduce the need for jigs.

• Repeatable: Great for building multiple identical bots or testbeds.

• Good for Non-Metal: Works well with plastic or wood prototypes.

Cons

• Hard to Modify: Once joined, the structure isn’t easily reconfigurable.

• Flex Risk: Thin materials may wobble or deform under load.

• Cutting Precision Needed: Slots and tabs must be toleranced correctly for your cutting process.

FTC Tips

• Add ~0.1–0.2mm clearance between tabs and slots depending on cutter type.

• Use interlocking fingers or “keyed” features to lock parts rotationally.

• Add fillets or dog-bones to inner corners to match laser/waterjet cut radius.

• Secure tabs with nylon lock nuts or rivets—design so they sit flush to avoid snagging.