Design and Fabrication of a Pegboard With Toggle Clamp Fixture for Precision Welding

Abstract

Precision welding plays a critical role in modern manufacturing industries, where dimensional accuracy, repeatability, and structural integrity are essential. This thesis focuses on the design and fabrication of a modular pegboard integrated with toggle clamp fixtures to improve the precision, stability, and efficiency of welding operations. The primary aim is to develop a cost-effective, flexible, and reusable welding fixture system that enhances the accuracy of joint alignment and reduces setup time across various welding applications. Fabrication involves the use of mild steel plates for the pegboard and high-strength toggle clamps to withstand mechanical stress. The results demonstrate significant improvements in weld accuracy, operator safety, and productivity, confirming that the proposed system is effective for use in small- to medium-scale fabrication workshops. This thesis concludes that the pegboard with toggle clamp fixture is a versatile, scalable, and user-friendly solution for precision welding applications. It also provides recommendations for future improvements, such as automation integration and material optimization, to enhance functionality and performance further.