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SCRAP SMARTS
Prevent costly scrap by aligning design with real-world die behavior.
Issue 069
⚠️ Avoidable Scrap
If you’re launching a new stamped component—especially one that’s plated, bent, or overmolded—you know the panic of finding out a part doesn’t meet spec after tooling’s already built.
And the reality? Most of those issues don’t show up in the pressroom—they show up in the assumptions made upstream. A missed tolerance, an underdefined plating spec, or an overambitious CAD model can lead to scrap, delays, and “why didn’t anyone catch this sooner?” moments.
🦸 The Hidden Hero
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.
🧭 The Gromax Lens
What pre-production feedback actually looks like
When stamping experts are looped in during early design and tooling review, a lot of “inevitable” problems suddenly become avoidable.
In one recent example, a control module terminal required a tightly plated contact zone and tight form control to avoid interference in an insert-molding tool. If we’d followed the original print without review, the team risked a double-digit scrap rate due to misalignment in the molded cavity.
Instead, early collaboration led to:
• A revised plating mask design to control overrun
• A tweak to the bend sequence to maintain flatness
• A targeted tolerance strategy that realistically held ±0.0015” in production
The result? Consistent mold fit, a smoother launch, and scrap below 1%. No redesign. No last-minute ECOs (engineering change orders).
🔧 Plan Early. Build Smart. Win Big.
Collaborative tooling isn’t overhead—it’s insurance.
We get it—tooling reviews don’t always feel urgent. But skipping them is like skipping torque checks before a test drive. The issues don’t show up right away, but they will.
Here’s a real-world checklist we use with customers:
✅ Replace CAD defaults with real, achievable tolerances
✅ Clarify plating specs, especially masking and contact zones
✅ Consider how forms and bends impact plating and molding
✅ Ask your die builder what they’d change—chances are, they already know
Prevention costs less than correction. Every time.
🌟 What Success Looks Like
Less scrap. Fewer delays. Better launches.
You don’t need to overhaul your process. You just need smarter inputs early on. That’s what separates high-yield programs from high-stress ones.
When toolmakers, platers, and molders speak the same language early, it’s easier to deliver parts that fit, function, and pass inspection—without the back-and-forth.
Bonus? When your project requires RoHS, ITAR, or DFARS compliance, early feedback also ensures your part strategy aligns with audit-proof documentation and vendor traceability.
Tired of Avoidable Surprises?
Tell us what you're working on—our engineers will review your prints and help flag any manufacturability risks. No strings. Just better starts.
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.