With the mounting concept established, the next step was converting the constraint strategy into physical components. The system required structural elements capable of maintaining panel position while interacting with the console geometry identified in the previous stage.

Rather than relying on a single mounting component, the design moved forward with two independent brackets positioned along the panel length. Separating the structure into front and rear elements simplified fabrication while allowing the mounting system to accommodate slight variations in console geometry.

Each bracket would interface with the MOLLE panel while extending inward toward the console to establish the compression-based constraint system described previously.

Bracket Architecture

The prototype system consisted of two sheet metal brackets, located near the forward and rear edges of the panel.

Each bracket served two primary functions:

·         Panel Interface

o   The outer face of the bracket aligned with the mounting holes on the panel.
Bolts passed through selected holes and secured the panel to the bracket using serrated flange nuts with thread locker.

o   This avoids reducing available mounting surface on the panel.

·         Console Interface

o   The inner geometry of each bracket extended toward the console structure.
Through controlled bends, the brackets positioned contact surfaces that interacted with the console’s existing geometry.

o   When assembled, these surfaces contributed to the compressive retention system described in the previous entry.

Material Selection

The prototype brackets were designed for fabrication from 5052 aluminum sheet with a thickness of 0.08 in (approximately 2.0 mm).

5052 was selected due to its suitability for sheet metal applications requiring forming and moderate structural stiffness. The material provides good bend characteristics while maintaining sufficient rigidity at this thickness for the expected loads applied to the panel.

At 0.08 in thickness, the brackets could be produced using standard sheet metal bending operations while maintaining structural stability for typical interior vehicle use.

Manufacturing Considerations

The bracket geometry was developed with conventional sheet metal fabrication processes in mind. The goal was to produce components that could be manufactured using straightforward bending operations without secondary machining.

Key considerations included:

• Bend geometry compatible with common press brake tooling
• Controlled bend radii appropriate for 5052 aluminum
• Flat mounting surfaces aligned with and cleared the MOLLE slot grid
• Clearance for bolt heads and installation tools

Because the mounting concept depended on geometric interaction with the console, dimensional accuracy and bend consistency were expected to influence overall system fit.

Initial Assumptions

The prototype bracket design was based on several assumptions that required validation during physical testing:

• The console trim could tolerate light compressive contact without deformation.
• The two-bracket architecture would provide sufficient resistance to panel rotation.
• The MOLLE slot interface would distribute loads across the panel structure.
• The bracket geometry would maintain consistent positioning despite small variations in console dimensions.

These assumptions would ultimately be verified through prototype fabrication and installation testing.

Next Step

With the prototype bracket geometry defined, the next stage of development involved producing initial components and evaluating their fit within the console environment.

Because the mounting system relied heavily on geometric interaction with the console structure, early testing was expected to reveal areas where bracket shape, contact locations, or clearances required adjustment.

These adjustments and subsequent refinements would become the focus of the next stage of development.