Cord Management Tray

Summary
I designed and built a steel cord management tray that mounts under a desk and supports power strips, cables, and adapters. I modeled the tray in SolidWorks, plasma cut the flat pattern, bent it on a press brake, and welded it into shape. I also machined the threaded mounting hardware on a CNC lathe for an accurate fit. The finished tray is strong, functional, and sized to keep cables organized and out of sight.

Goals
My goals were to create a durable, clean looking tray that could hold the weight of cords and power supplies. I wanted the design to be simple to fabricate with common shop tools while still looking professional. I also used the project as practice in several processes: sheet metal modeling, plasma cutting, bending, welding, and threading parts on the CNC lathe. The final goal was a tray that fit tightly under the desk and kept everything secure without sagging.

Challenges
A main challenge was making sure the steel structure was stiff enough to hold weight without bending. This required planning the bend angles, flange sizes, and overall geometry so the tray stayed rigid after welding. Another challenge was dealing with the dimensional changes caused by plasma cutting, press brake bends, and welding heat. Each step could shift the part slightly, so I measured often to keep the build aligned with the SolidWorks model.
Machining the threaded hardware also required attention, since the threads needed to fit smoothly and carry the load. Tooling choices, feeds, and depth control all mattered. In the end, the tray mounted securely and supported the weight as intended.

Details

Sheet Metal Geometry: Plasma Cutting, Bend Allowances, and Layout
The tray began as a flat steel profile modeled in SolidWorks with all bend lines and cutouts included. Because plasma cutting creates a wider kerf, I added enough tolerance for the bends and welds to line up later. I calculated bend allowances before cutting so the final dimensions matched the model. The flange sizes were chosen for strength and for consistent bending, which helped keep the final shape square and even.

Press Brake Forming: Accuracy and Rigidity
Each bend needed to land at the correct angle for the tray to stay strong. I used a standard die with an inside radius close to the model and checked the angle after the first bend to keep everything aligned. As the bends formed the channel shape, the tray became more rigid, and by the fourth bend it already had enough stiffness to support cables and power supplies.

Welding and Assembly: Distortion Control and Alignment
After bending, I welded the joints to lock the tray into its final shape. To avoid warping the thin steel, I spaced out the welds, allowed cooling time, and worked from opposite sides. Once welded, I cleaned the joints and checked that the tray was square and sat flat. The welded corners added the strength needed for real load support.

CNC Lathe Hardware: Threading and Fit
I machined the mounting hardware on a CNC lathe to get accurate threads and a smooth fit. The hardware needed to hold weight, so I cut the threads carefully and checked the fit before installation. Once tightened, the hardware pulled the tray securely against the desk.

Final Integration: Strength and Cable Organization
The finished tray held its shape under load because of the steel material, the bend geometry, and the welded reinforcement. When mounted under the desk, it provided space to route cords and store power adapters while staying hidden and secure. The project brought several fabrication processes together into one clean and functional cable management solution.

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