The challenge
The customer — a tier-1 automotive supplier — arrived with a single prototype of an electronics enclosure and a goal: validate the design, then scale to a repeatable 500-piece run without the per-part cost climbing or the fit drifting between batches.
Three things made it harder than it looked:
- Cost-driving geometry — deep pockets and a few over-tight tolerances that weren't actually critical to function.
- Consistent sealing face — a flat mating surface and bore pattern that had to repeat across every part.
- Cosmetic finish — a clean anodized surface with no machining marks on visible faces.
Our approach
We started with a DFM review before quoting production. Working from the model and drawing, our engineers proposed changes that kept the part's function intact while taking out cost.
The result
The redesign and process plan met the customer's cost and quality targets, and the part moved from prototype to production without re-engineering.
With critical dimensions confirmed up front and a dedicated fixture, fit stayed consistent across all 500 pieces, the anodized faces came out clean, and the customer now reorders the part on a standing schedule.
Capabilities used
- 5-axis machining — body machined complete in one setup.
- DFM & engineering support — tolerance triage and geometry optimization.
- Surface finishing — clear anodize on cosmetic faces.
- Quality assurance — CMM first-article and in-process inspection with records.
