Project Description


We are frequently challenged to solve a demanding problem for our customers. This application required our supplier to evaluate the customer’s existing design, create a DFM (design for manufacturing) roadmap, tool and deliver parts for mass production in less than 8 weeks.


  • Automotive application required TS16949
  • Multiple SKU possibilities required by customer
  • Cosmetic appearance of surface and light refraction through lens
  • Achieve aggressive schedule and cost target

Services Performed

  • Engineering study and DFM (design for manufacturing)
  • Industrial design
  • Tool design for optimizing materials compatibility


  • DFM identified both production and performance design improvements
  • One tool designed for inserts achieved all SKU’s
  • Tooling for prototypes achieved in 3 weeks, under budget
  • Quality and cosmetic appearance goals acheived

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