Case Study: Improving Custom Spring Clips By Design

In the realm of manufacturing, custom metal clips and brackets often play crucial roles in assembly and function. Unfortunately, these components can sometimes be difficult to design if your not submerged in building them from day to day. Issues during installation can slow down production and lead to increased costs. In this case study, we will explore how we improved the design of the custom spring clips and kept manufacturing cost down.

Understanding the Problem

Upon reviewing the client's current metal clip design, it became evident that the clips were problematic during installation. They did not fit correctly, resulting in misalignments and necessitating the use of a tool for removal. The design was inefficient for metal stamping or fourslide stamping production.

Through detailed analysis, we discovered that the primary issue was a combination of stack dimensions and shapes that failed to meet the required tolerances of the mating pieces. Furthermore, the existing design created stress points that could lead to potential failures overtime. The client was looking for a solution to address these problems without increasing production costs.

Close-up view of redesigned metal clip / brackets showcasing improved features.

Above is a close up view of original metal clip

Our Approach to the Design Challenge

Our team adopted a systematic approach to tackle the design issues. We began with a detailed consultation with the client to gain a full understanding of their needs. This included discussing their expectations for the spring clips, the typical installation process, as well as any feedback they had received from the assembly line workers.

Next, we used CAD (Computer-Aided Design) software to model the original clip. This allowed us to visualize the problematic areas and explore various options for redesigning them. The mating pieces of the clips where also shared so we could analyze the any stack tolerancing and adjust the new design accordantly.

We proposed creating features that would facilitate correct alignment during installation, thus minimizing human error. Our approach was to keep both quality and cost-effectiveness in mind, ensuring that we used materials suitable for our fourslide progressive die stamping manufacturing process that kept expenses manageable.

Next, we made protypes from the same material to be used on the final product for the customer to further examine. The sheet metal prototypes closely resembled what the final product would be during the mass phase of production.

Key Improvements in the Custom Spring Clips

The redesigned custom metal clips and brackets offered several key improvements:

1. Enhanced Fit: The new geometry allowed for easier alignment and installation. Components could be securely fastened without extra effort or adjustments.

   
   

2. Stress Distribution: The updated design included features that distributed stress more evenly, reducing the risk of failures and enhancing longevity. By removing sharp edges and points where stress was concentrated, we created a more durable part.

   
   

3. Cost Efficiency: With our history of fourslide progressive die stamping and manufacturing techniques, we managed to keep production costs within the client’s budget while enhancing the metal spring clip's quality.

   
   

View showcasing installed of new metal clip.

Positive Impact on the Client's Operations

After the new custom metal clips were implemented, the client reported improvements in their operations. Installation was improved, resulting in reduced labor costs. Moreover, the alignment issues were now a thing of the past and the use of any tools to de-install was no longer required.

Qualitative feedback was overwhelmingly positive. It was noted that the new design not only simplified their tasks but also enhanced their confidence in the assembly process. The custom metal clips now integrated seamlessly with other components, leading to increased overall efficiency.

The Value of Innovative Design Thinking

What sets our services apart from others in the industry is our commitment to thinking outside the box. We understand that clients are not just looking for parts; they seek partners capable of delivering solutions to their unique projects. By leveraging our deep industry knowledge and experience, we can challenge conventional designs and offer innovative alternatives.

In today's competitive market, it is essential for manufacturers to address and resolve issues efficiently. Whether it's through innovative design revisions or cost-saving measures, our goal is to be a partner that clients can rely on to enhance their operations. Our team is dedicated to improving products without sacrificing performance or affordability, a balance that many suppliers may struggle to achieve.

Your Next Steps with Us

If you are currently facing challenges with custom metal clips and brackets or seeking a reliable supplier that will bring creative solutions to the table, look no further. Our expertise lies in understanding your needs and reshaping designs that can transform your operations.

At Amtech, we pride ourselves on collaborative partnerships that foster success and growth. We invite you to reach out, share your challenges, and discover how our innovative designs can benefit your manufacturing processes. Our fourslide operation is conveniently located in the Northwest and serves customers worldwide.