Haizol Global was tasked by a multinational retail customer, operating across the US, Germany, the UK, and Russia, to optimise the design and production of a complex magnetic component. Their request underwent 13 quotation rounds and 12 drawing revisions to make sure that the end-product met their stringent requirements.
Engineering Challenge: Eliminating Costly Waste
The customer's original part included a copper strip inserted between two stamped iron sheets. This was an element that would ultimately be discarded during final assembly.
Our engineering team proposed a design revision that eliminated the strip altogether. Thereby reducing raw material usage and simplifying the assembly process.
Additional improvements included:
- Redesigning upper and lower iron sheets for material efficiency and cost savings.
- Creating a grooved packaging fixture to stabilise the magnet bar and prevent sliding.
What Manufacturing Methods Were Used?
We connected the buyer with factories that specialise in precision die stamping and magnetic assembly. The factories were selected based on criteria. 1) They had strong resource integration capabilities 2) Deep process knowledge, and 3) their emphasis on long-term collaboration over short-term profit.
The component required a multi-step approach:
- Die stamping for shaping the small iron sheets.
- Cutting and shearing for long metal strips.
- Powder metallurgy for manufacturing the magnetic elements.
- Deburring and chamfering to ensure safety and surface finish.
Apart from those processes. Manual assembly required special care, due to the use of magnets with opposing polarities. Our technicians followed strict alignment protocols to avoid repulsion during insertion.
To prevent movement during global transit, we developed a tailored packaging system:
- Cardboard trays with custom grooves to hold parts securely.
- Cable ties to minimise internal shifting and absorb shock.
Result: Repeat Orders from a Satisfied Customer
So what was the end result? The final component met all mechanical, cost, and delivery targets. As a result, the customer continued with repeat orders across all regional branches, validating the long-term value of supplier collaboration and early-stage design feedback.
Key Takeaways for Engineers and Buyers
- Use die stamping with powder metallurgy when you need both precision and magnetic performance. This combination is especially useful for compact assemblies.
- Small design tweaks early on, such as removing redundant materials, can lead to big savings in production.
- Work with stamping die manufacturers who welcome back-and-forth on design. That flexibility up front can help you avoid mistakes and scale up smoothly.
Work with Haizol on Your Next Precision Stamping Project
Haizol Global is a one-stop supply chain sourcing solution that provides instant manufacturing services. Our engineers help you:
- Eliminate unnecessary materials.
- Reduce tooling and assembly costs.
- Validate concepts through iterative quoting and design.
Do you need help reducing costs or refining your stamping die design? Schedule a free consultation with our engineering team to explore design alternatives, material optimisations, or tooling strategies for your part.