Metal frame and method for manufacturing the same

A method for manufacturing a metal frame having at least first and second sides, comprising the steps of:

• (a) blanking a plurality of individual metal segments generally in the form of simple shapes so that they can be tightly arranged on a piece of sheet metal stock to minimize the amount of scrap material produced;
• (b) welding the plurality of individual metal segments to form a welded blank assembly, wherein the welded blank assembly includes segments of the first side and segments of the second side joined together in an edge-to-edge arrangement that lacks overlapping joint areas;
• (c) stamping the welded blank assembly to form a stamping assembly that has a different perimeter than the welded blank assembly;
• and
• (d) forming the stamping assembly into the metal frame by bending the stamping assembly so that the first and second sides are joined by a shared metal segment that is bent along its length to form a corner having a smooth transition.

A metal frame for use with a piece of movable equipment, comprising:

• a first side window panel having a first plurality of blanked metal segments that are welded together;
• a second side window panel having a second plurality of blanked metal segments that are welded together;
• and
• a center windshield panel having a third plurality of blanked metal segments that are welded together, wherein the first side window panel and center windshield panel share a first elongated vertical pillar that is bent along its length to form a first corner that extends between the first side window panel and center windshield panel in a smooth transition, and the second side window panel and center windshield panel share a second elongated vertical pillar that is bent along its length to form a second corner that extends between the second side window panel and center windshield panel in a smooth transition.