Aluminum & Steel Control Modules for the Automotive Industry
Savings Provided: $1,000,000
Perfection Spring & Stamping Corp. was contracted to manufacture a large series of steel bracket assemblies for the automotive industry. This bracket assembly consisted of three mounting legs per component and a cover bracket that was originally die-casted. Through prototyping and development testing, our team of engineers established that this expensive die casting process could be replaced with a drawn metal stamping operation manufactured with both Aluminum and Steel options. This solution provided a better product at considerable cost savings!
Offering a more stable metal forming procedure, drawn metal stamping eliminated the need for other secondary operations and fasteners. Moreover, with the ability to maintain tighter tolerances - as well as provide better transfer of heat in extreme temperatures to meet the customer's RFI/EMI requirements - this process yielded a higher quality product. Additionally, the progressive die replaced the need for expensive maintenance costs associated with die-cast tooling. When the results were tabulated, this solution generated annual cost savings equal to $200,000 per year over the five-year program, providing our customer with a total savings of $1,000,000.