A free DFM review that saved $18,000 in rework
A German engineering team was about to release a housing with a thin wall and a stress-rising sharp corner. Our free DFM review caught both before cutting — avoiding an estimated $18,000 in rework on the batch.
Background
A German engineering team had a machined housing design ready to release to production. On paper it looked complete, but two manufacturability problems were waiting to cause scrap once cutting started.
The challenge
The design carried a wall thinner than the process could hold reliably, risking distortion and chatter, plus a sharp internal corner that concentrated stress and could not be cut cleanly with a standard tool. Neither issue was obvious from the drawing alone.
Our approach
- 1
Ran our standard free design-for-manufacturability review on the uploaded CAD before quoting for production.
- 2
Flagged the thin wall and recommended a 0.3 mm increase to keep the part rigid during machining.
- 3
Flagged the sharp internal corner and proposed a fillet sized for a standard, rigid end mill.
- 4
Confirmed the revised design, then ran the production batch.
Quality & inspection
Both changes were agreed with the customer's engineers before any material was cut, turning a likely scrap-and-rework cycle into a clean first run.