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DESIGN SMARTER
Cut cost without cutting quality using precision-first design principles.
Issue 067
⚠️ The Hidden Cost of “We’ll Fix It Later”
If you’re designing insert-molded terminals, pressure sensor housings, or grounding clips, you’ve probably said this:
“We’ll clean it up in tooling.”
But pushing design problems downstream can be significantly more costly than addressing them early. The reality is, once a die is built, even small design oversights can lead to rework delays, additional tooling expenses, or performance issues that ripple through sourcing and production.
And it’s not just dollars—it’s confidence. When design decisions introduce last-minute surprises, it stresses your team, the supplier, and your timeline.
🧭 You’re the Hero—Not the Hold-Up
As a product engineer, you’re not just delivering a part—you’re defining how that part behaves from sketch to scale. Your early choices directly affect tooling complexity, cycle time, and secondary operations.
One customer we worked with—developing an aerospace terminal—came in with a design that had multiple forming features. By walking through the actual function of each feature, we were able to eliminate several that didn’t add value. The result? A simpler die, fewer forming stations, and weeks saved on lead time.
That’s the power of DfM—not compromise, but clarity.
🧠 A Smarter Lens: Design for What’s Possible
You don’t have to become a tooling expert. But knowing where stamping adds cost—or can unlock value—makes you a sharper engineer. Start with these principles:
🔩 Function-Driven Features
Ask: “Is this geometry critical to function, or legacy CAD?” Cut unnecessary forms early.
📐 Tolerance Check-In
Tolerances under ±0.002” add cost and time—unless they’re critical to assembly, electrical contact, or regulation. If it’s cosmetic or non-mating, consider relaxing.
🔋 Secondary Ops Awareness
Choose materials and features that minimize downstream steps. Pre-plated stock or tapped-in-die operations can reduce variation and cost.
🛠 Loop in Your Toolmaker Early
A quick CAD review with your stamping partner can uncover form/fit issues, burr risks, or tolerance stack-ups before they hit the die shop.
These aren’t big moves—they’re smart, early pivots that prevent firefighting later.
🚀 The Launch Everyone Wants
When you design with manufacturing in mind, everyone downstream feels it:
✅ Tool builds are faster and smoother
✅ Production starts with fewer surprises
✅ Quality teams see fewer adjustments
✅ Sourcing teams don’t scramble to find alternate vendors mid-project
It’s not just a better part—it’s a better process. And you made it happen.
Got a design snag?
Share your experience—Gromax experts are happy to offer insights or advice on how to smooth out your next launch.
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.