Aerospace Bracket Redesign — 40% Cost Reduction
Redesigned a complex welded assembly as a single 5-axis machined part, eliminating 12 welding operations and reducing cost by 40%.
The Challenge
The customer's legacy bracket was a 14-piece welded assembly requiring 12 weld operations, multiple suppliers, and 3 weeks of lead time. Weld distortion caused inconsistent hole positions, and every lot required manual rework. They needed a lighter, more repeatable solution without sacrificing structural performance.
Our Approach
- 01
Our engineering team analyzed load paths and consolidated 14 components into a single monolithic design optimized for 5-axis machining.
- 02
We eliminated all welds by using pocketing and rib structures that maintain stiffness while reducing weight by 50%.
- 03
A single 5-axis setup replaced five 3-axis operations — one fixture, one program, one inspection cycle.
- 04
First Article Inspection per AS9102 with full dimensional report delivered before production release.
“The redesign exceeded our expectations. We went from a multi-supplier welded assembly to a single machined part with better repeatability and half the weight.”
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