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Engineering Design & Pre-Production
Design For Manufacturability Starts Here.
Gromax engineers collaborate directly with your team to optimize component geometry, materials, and tolerances—reducing rework, tooling changes, and downstream process inefficiencies.
Capabilities
Technical Capabilities Aligned with Real-World Production
Design for Manufacturability (DFM)
Design For Manufacturability (DFM)
Comprehensive feedback on part features, geometry, tolerance schemes, and carrier strategies to ensure stamping feasibility across production volumes.
3D CAD Modeling & Simulation
3D CAD Modeling & Simulation
Parametric CAD development with support for FEA, springback prediction, and strip layout simulation. Files prepared for downstream CAM and toolpath generation.
Reverse Engineering & Tooling Legacy Support
Reverse Engineering & Tooling Legacy Support
Reconstruct components and dies from samples or partial data using 3D scanning, CAD rebuild, and functional updates to meet current spec and material standards.
Material Selection & Thickness Optimization
Material Selection & Thickness Optimization
Material consulting across copper alloys, stainless steels, phosphor bronze, brass, and beryllium copper—with selection based on conductivity, mechanical strength, plating compatibility, and compliance requirements (RoHS, DFARS, ISO 13485)
Feasibility & Cost Analysis
Feasibility & Cost Analysis
Evaluate material utilization, station count, secondary process elimination, and total cost drivers early in the design stage to inform tooling and sourcing decisions.
Industry
Application
Designed for Precision in Regulated and Performance-Critical Industries
Electrical & Power
+ DFM input for high-current busbars, terminals, and connectors.
+ Conductivity, thermal performance, and creepage/clearance optimization.
+ Strip layout design for high-speed, automated stamping operations.
+ Conductivity, thermal performance, and creepage/clearance optimization.
+ Strip layout design for high-speed, automated stamping operations.
Results
+ Fewer design revisions during validation
+ Optimized current paths and improved thermal reliability
+ Faster integration into automated assembly lines
+ Optimized current paths and improved thermal reliability
+ Faster integration into automated assembly lines
Electronics & Sensors
+ Precision design of spring contacts, EMI shields, and micro terminals
+ Springback and form consistency analysis for thin-gauge materials
+ Conductivity and plating compatibility built into material selection
+ Springback and form consistency analysis for thin-gauge materials
+ Conductivity and plating compatibility built into material selection
Results
+ Improved electrical performance and contact reliability
+ Extended cycle life in high-wear or high-frequency environments
+ Reduced variation and scrap in high-volume production
+ Extended cycle life in high-wear or high-frequency environments
+ Reduced variation and scrap in high-volume production
Defense & Aerospace
+ Compliance with defense procurement and documentation standards
+ Faster design validation and first-pass approval
+ Reliable performance in mission-critical, high-stress environments
+ Faster design validation and first-pass approval
+ Reliable performance in mission-critical, high-stress environments
Results
+ Compliance with defense procurement and documentation standards
+ Faster design validation and first-pass approval
+ Reliable performance in mission-critical, high-stress environments
+ Faster design validation and first-pass approval
+ Reliable performance in mission-critical, high-stress environments
Medical Device & Equipment
+ Components for Class II and III medical assemblies and sensor interfaces
+ Tight-tolerance forming, burr-free edge control, and biocompatible materials
+ Design control workflows aligned with ISO 13485 and risk management processes
+ Tight-tolerance forming, burr-free edge control, and biocompatible materials
+ Design control workflows aligned with ISO 13485 and risk management processes
Results
+ Fewer validation delays during regulatory submission
+ Consistent fit and finish in device-critical components
+ Reduced reliance on manual finishing or secondary processes
+ Consistent fit and finish in device-critical components
+ Reduced reliance on manual finishing or secondary processes
Industrial Machinery
+ Stamped brackets, supports, housings, and clamps for heavy-duty assemblies
+ Material choices based on mechanical loading, wear, and corrosion environments
+ Tolerance analysis and mounting alignment for assembly compatibility
+ Material choices based on mechanical loading, wear, and corrosion environments
+ Tolerance analysis and mounting alignment for assembly compatibility
Results
+ Longer service life with durable and form-stable parts
+ Minimized misalignment in mechanical and fluid systems
+ Cost-effective production of rugged components at scale
+ Minimized misalignment in mechanical and fluid systems
+ Cost-effective production of rugged components at scale
Molding-Integrated Applications
+ Leadframes, inserts, and terminals designed for insert and overmolding
+ Retention features, undercuts, and alignment tabs for mold compatibility
+ Validation of thermal and mechanical bonding between metal and resin
+ Retention features, undercuts, and alignment tabs for mold compatibility
+ Validation of thermal and mechanical bonding between metal and resin
Benefits to Your Team
+ Stronger metal-to-plastic interface and resin flow performance
+ Fewer molding defects such as short shots or voids
+ Reduced cycle times through precise, mold-ready insert geometry
+ Fewer molding defects such as short shots or voids
+ Reduced cycle times through precise, mold-ready insert geometry
Quality Systems & Compliance
ISO 9001:2015 Certified
Gromax maintains a certified Quality Management System (QMS) under ISO 9001:2015, ensuring documented processes for design control, inspection, corrective actions, and continuous improvement across all production stages.
ITAR Registered Facility
Registered with the U.S. Department of State under the International Traffic in Arms Regulations (ITAR), Gromax is authorized to handle defense-related technical data and manufacture parts for military and aerospace applications requiring export control compliance.
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In-House DFM, CAD, and Revision Control Workflows
All engineering activities—from strip layout design to die simulation—are performed in-house, with formal version tracking and ECN (Engineering Change Notice) control. CAD data is maintained with full traceability for tooling and production consistency.
FAIR, PPAP, and Regulatory Submission Support
Gromax supports First Article Inspection Reports (FAIR) per AS9102, Production Part Approval Process (PPAP) per AIAG standards, and custom documentation packages for FDA, ISO 13485, and customer-specific compliance audits.
DFARS-Compliant Material Sourcing
When required, Gromax sources materials in compliance with the Defense Federal Acquisition Regulation Supplement (DFARS), ensuring traceability to qualified U.S. or allied-country mills for aerospace and defense programs.
Featured
Case Study
THE CLIENT
Ohio U.S.-Based Electrical Equipment Manufacturer
Produces UL-listed switchgear, control panels, and circuit protection assemblies
Serves industrial and commercial power distribution markets
ISO 9001-certified with a qualified vendor base for custom components
THE CHALLENGE
Copper terminal strip required manual forming after stamping.
Material yield loss over 20% due to inefficient strip layout.
High-volume demand created bottlenecks in assembly.
Needed a DFM-ready redesign to reduce cost and improve. manufacturability without affecting electrical specs or UL traceability
THE SOLUTION
Conducted full Design for Manufacturability (DFM) review
Introduced in-die forming for bend features, eliminating manual bending
Optimized strip layout, improving raw material usage by 17%
Redesigned carrier tabs to stabilize part during high-speed stamping
Verified new design through CAD simulation and C110 copper sample runs
THE RESULTS
22 seconds saved per unit in downstream assembly
17% improvement in copper material yield
14% total part cost reduction
First-article parts delivered in 3 weeks, supporting ramp-up timeline
Start with Engineering That Reduces Risk...
Need help with a new part, a tooling rebuild, or a quote for stamped components?
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