Metal Part Design Optimization: Start by Finding Hidden Flaws

A drawing that looks complete can conceal critical flaws—such as insufficient bend radius, overstretched material in stamping, or welding interference. These issues cause mold damage, high scrap, and late deliveries once in production.

Therefore, we proactively identify and rectify these problems: not only do we fabricate according to the drawings, but we also help customers with metal part design optimization before the construction begins.

Next, we will demonstrate how we can assist you in perfecting each metal part.

 Reviewing the Drawings — Introduce Experience in Advance

When we receive a new part drawing, the first step is to hold an internal DFM review. The engineers will conduct simulation-based verification of the parts’ manufacturability. They will examine the following items one by one:

• Is there a narrow interference zone at the bending point?
• Will the rounded transition in stamping/deep stamping cause cracking?
• Will the sharp corners in the laser cutting path lead to overheating and burn-off?
• Has the welding position reserved the operation space for electrodes or welding guns?

These review results will be sent back to the clients.

 **Common Drawings “Flaws” and Corresponding Optimization Solutions

Full-Process Fabrication Enables Optimization

We can provide tailored adjustment plans for our customers based on their needs. Since all the manufacturing processes are carried out in our 9,000-square-meter factory. There is no need for outsourcing, and the customers don’t have to coordinate with another supplier.

In addition to the sheet metal-related processes such as bending, stamping/Deep Stamping, laser cutting, welding, and surface treatment (with two production lines), we also offer:

– CNC Machining: 2 five-axis CNC machining centers + 3 vertical machining centers

– Metal Casting: Complete set of foundry equipment

Auxiliary equipment: 3 sets of pipe bending machines, 4 sets of laser marking machines, 12 sets of drilling machines

Click for full equipment list.

This means that whether your part is made of carbon steel or stainless steel, we can complete all the fabrication work from raw materials to finished products under the same roof.

This closed-loop capability is key to efficient metal part design optimization — engineers know upfront whether shop-floor equipment can execute their suggestions perfectly.

The actual gains brought about by optimization

An automotive parts company provided us with a drawing of a foldable jack support. The engineers estimated that the scrap rate in the pipe cutting and forming process was as high as 12%.

Our engineers adjusted the welding points and edge force parameters. It was suggested that the main structure use Q235/45 steel, the pins and safety pins use medium-carbon steel, and the surface coating use polyester powder coating.

Ultimately, the scrap rate dropped to 3.8%, the single-piece fabrication time was reduced by 22%, and there was no need to increase mold costs.

Optimize the drawings in advance to avoid waste after mold production—a free design review once to help you optimize costs.