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Engineering ROI: How Better Design Saved ₹12 Lakhs ($14,000) in Manufacturing Tooling Costs

  • Kunal Bijlani
  • Jun 2
  • 3 min read

In the world of product development, the spotlight often falls on the final product: its features, its aesthetics, and its market impact. But behind every successful product lies a critical, often overlooked, phase: manufacturing tooling. This is where initial design decisions can either quietly multiply costs or, conversely, unlock massive savings.


At iNSPIRE Design, we believe in Engineering ROI – demonstrating a tangible return on investment through smart, strategic design. We recently had a perfect case study that highlights this principle, where a seemingly minor design optimization resulted in a staggering ₹12 Lakhs (approximately $14,400 USD) in direct manufacturing tooling cost savings.



The Challenge: A Complex Part, Costly Production

We were approached by a client with a new product that involved a critical component – a complex plastic part with intricate internal geometries. The initial design, while meeting functional requirements, presented a significant hurdle for mass production.


The traditional approach to manufacturing this part would have necessitated a multi-cavity injection mold. This meant:

  1. Multiple Slides and Lifters: Due to undercuts and complex features, the mold would require numerous moving parts (slides and lifters) to eject the component without damage. Each slide adds substantial complexity, increases manufacturing time for the mold itself, and significantly drives up costs.

  2. High Maintenance: More moving parts also translate to higher maintenance costs and potential downtime during production.

  3. Extended Lead Time: Designing and fabricating such a complex mold would take a considerable amount of time, delaying market entry.

  4. Exorbitant Tooling Costs: The estimated cost for this traditional multi-cavity mold ran into several tens of lakhs.


The projected tooling cost for this one component alone was a major concern for the client, threatening the overall profitability and viability of the product.


The iNSPIRE Design Solution: Ingenious DFM & Optimized Geometry


Our team at iNSPIRE Design, specializing in Design for Manufacturability (DFM) and advanced engineering, took a deep dive into the component's geometry. We didn't just accept the initial design as a fixed requirement. Instead, we asked: "How can we achieve the same functionality while simplifying its production?"




Our solution involved a subtle yet highly impactful design modification:

  • Strategic Feature Re-design: We meticulously analyzed each intricate feature and undercut. Through intelligent re-design, we were able to incorporate a very small, carefully placed "split line" and adjust certain wall thicknesses and radii.

  • Eliminating Slides: This seemingly minor alteration eliminated the need for four expensive hydraulic slides in the injection mold. By leveraging the natural parting line and designing the features to "pull" out of the mold without complex movements, we transformed a multi-slide mold into a much simpler, more robust two-plate mold.


The ROI: ₹12 Lakhs Saved, Production Accelerated


The impact was immediate and profound:

  • ₹12 Lakhs Direct Savings: By eliminating four slides, the cost of manufacturing the injection mold itself dropped by an estimated ₹12 Lakhs. This was a direct saving on the client's capital expenditure for tooling.

  • Reduced Lead Time: A simpler mold is faster to design and fabricate, significantly reducing the tooling lead time and accelerating the product's journey to market.

  • Lower Maintenance: Fewer moving parts mean a more reliable mold, less wear and tear, and reduced long-term maintenance costs during mass production.

  • Improved Efficiency: A simpler mold runs more efficiently, potentially leading to faster cycle times and higher output.


This example clearly demonstrates that investing in intelligent design upfront, particularly with a focus on DFM, isn't an added expense – it's a strategic investment that yields a massive Engineering ROI. It's about looking beyond the functional requirement to optimize the entire lifecycle of the product, from concept to cost-effective mass production.



At iNSPIRE Design, we pride ourselves on delivering not just innovative products, but also smart, manufacturable designs that directly impact your bottom line.


Is your product design optimized for manufacturing efficiency and cost savings? Reach out to us for a free consultation!



 
 
 

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