Reducing Part Cost Through Smart Design Consolidation
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- Source:VoltPart
In the competitive world of global manufacturing, particularly for CNCmachined components, controlling part cost is paramount without sacrificing quality. While optimizing machining parameters is a common approach, one of the most powerful yet underutilized strategies is Smart Design Consolidation. This process involves reengineering an assembly of multiple parts into a single, more complex monolithic component. For businesses engaged in batch production, this strategy offers a direct path to significant cost reduction and enhanced product performance.
Traditionally, assemblies are built from several separate pieces, each requiring its own CNC programming, setup, fixturing, and individual machining time. Each part also needs separate quality control checks and generates its own scrap risk. Furthermore, the assembly process itself incurs labor costs and introduces potential points of failure through interfaces, fasteners, and tolerance stackups.
Smart Design Consolidation leverages the advanced capabilities of modern 3, 4, and 5axis CNC machining centers. By designing a single part that integrates the functionality of multiple components, you effectively eliminate these cumulative costs. The benefits are substantial:
Reduced Machining Time: One complex part often takes less total machine time than the sum of multiple simpler parts, thanks to the elimination of repeated setups.
Lower Material Costs: Consolidating parts can reduce the total volume of raw material required and minimize waste.
Elimination of Assembly Labor and Hardware: No need for screws, bolts, or adhesives, and the associated labor to assemble them is removed.
CNC machining Improved Product Reliability: A monolithic part has no interfaces to loosen or wear, leading to greater structural integrity and consistency.
Simplified Supply Chain: Managing one part number instead of several streamlines procurement, inventory, and logistics.
A classic example is replacing a fabricated assembly of brackets, spacers, and plates with one intricately machined block of aluminum. What was once 5 separate parts, 10 fasteners, and an assembly step becomes a single, robust, and precisionmade component.
As a professional CNC machining factory, we specialize in collaborating with our clients at the design stage to identify consolidation opportunities. Our engineering team can analyze your existing assemblies and propose innovative, manufacturable singlepart solutions that are not only costeffective but also superior in performance. By embracing Smart Design Consolidation, you transform your manufacturing approach, turning complexity into a competitive advantage and driving growth through smarter, more efficient production.
Let us help you rethink your designs and unlock new levels of efficiency and cost savings in your batch production runs.