Manufacturability Case Study

Product development is arguably the most important stage of a products lifecycle and requires proper investing for long-term profitability.  The costs associated with altering a product later in the lifecycle increase exponentially as time goes on.  In some cases, companies request a complete redesign of a product in order to cut costs in the early manufacturing stages.


A previous client who manufactured medical devices approached QTI looking to cut manufacturing costs on their internal frame used for a generator.  Their original frame was welded, which also caused the sheet metal to warp leading to a lower quality product.  Their process was time consuming and inefficient.


The QTI design team established three goals:

  1. Eliminate the warping
  2. Design for manufacturability
  3. Reduce cost


QTI Design engineers solved the warping problem by adding flush rivets to hold the sheet metal frame together.  Eliminating the welding phase of their previous process accomplished the first goal.  The changes that the design team made the generator frame cost efficient meaning they could produce a higher volume at a lower price.  The new procedures lead to a much smoother process, which accomplished the second and third goal.  In fact, they were able to reduce the manufacturing cost by approximately 50%.  With the previous process, it would cost the company $321.61 per unit when they manufactured 500 units.  With the updated process, it would only cost $159.21 per unit when manufacturing the same number of units.

The mechanical engineers at QTI are experts in all aspects of manufacturability giving us an advantage over competition.  They research applicable concepts, develop 3D designs using SolidWorks, and create customized prototypes that are tested accordingly.  Quality Tool, the sister company of QTI, is a sheet metal manufacturer that provides the resources necessary to succeed.  With over 122,000 ft2 of facilities to utilize, our capabilities are endless. Contact us today to see how our engineers can help solve your problems.

Posted in Manufacturability.

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