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Material Matters
How To Avoid Costly Material Selection Mistakes in Manufacturing
Issue 033
Everything looked perfect in CAD, but when production started, problems emerged—warping, cracking, and part failures. The culprit? 
The wrong material choice.
Excessive springback – High-strength steels bend unpredictably, causing fitment issues. Warping in aluminum – Aerospace brackets distorted due to poor formability. Stainless steel galling – High friction caused premature tool wear and cracking. Copper oxidation – Uncoated connectors failed due to environmental exposure.
A simple oversight in material selection can lead to expensive redesigns, unexpected costs, and frustrating delays.
✈️ Real-World Scenario: A Costly Aerospace Mistake
An aerospace manufacturer chose 7075 aluminum for a lightweight bracket, assuming it would handle stamping like other aluminum alloys. But during production, it cracked under pressure. Why? 7075 has high strength but low ductility, making it unsuitable for complex forming.
✅ What They Should Have Done: Selected a 5000-series aluminum, which offers better formability while maintaining strength. This would have prevented cracking and costly rework.
Common Material Selection Pitfalls
❌ Assuming Strength = Formability
Just because a metal is strong doesn’t mean it will form well. Advanced High-Strength Steels (AHSS) can be incredibly durable but suffer from extreme springback, requiring additional forming adjustments.
❌ Ignoring Work Hardening
Some metals (like stainless steel) harden as they’re deformed, leading to tool wear and cracking. Annealed stainless steel is often a better choice for deep drawing.
❌ Overlooking Surface Sensitivity
Copper provides excellent electrical conductivity but oxidizes quickly. Without proper plating or coating, connectors can degrade in performance.
❌ Not Accounting for Thermal Expansion
Materials expand and contract at different rates. If you’re assembling components with both aluminum and steel, misalignment over time is a real risk.
How to Choose the Right Material the First Time
✅ Match the Metal to the Manufacturing Process
If stamping is required, choose metals with high ductility. If machining, consider work-hardening tendencies and tool wear. If welding, avoid metals prone to cracking from thermal stress.
✅ Consider Secondary Operations
Does the part need post-processing like anodizing, heat treatment, or plating? Some metals respond better than others, impacting longevity and cost.
✅ Use Material Simulation Software
AI-driven material selection and digital twin technology allow manufacturers to predict metal behavior before production—helping prevent costly surprises.
✅ Partner with Manufacturing Experts Early
Experienced engineers can flag potential material issues before production begins, avoiding costly trial-and-error iterations.
The Takeaway
Choosing the right metal isn’t just about weight or cost—it’s about how the material behaves in the real world. A simple oversight in material selection can snowball into expensive production issues, late deliveries, and frustrated customers.
Next time you’re selecting a material, consider not just what looks good on paper, but how it will behave on the production floor. A little foresight now can save thousands (or even millions) down the road.
Gromax Precision Die & Mfg., Inc. specializes in designing and manufacturing precision metal stamped parts and tooling, including progressive stamping dies and custom equipment. With an on-time delivery rate of 99.68% and a defect rate of just 0.066%, the company ensures exceptional reliability and quality.
Gromax is ISO 9001:2015 certified and ITAR registered, serving industries such as medical, defense, aerospace, industrial automation, and automotive with high-quality, innovative solutions.