Saving 35% on a Precision Metrology Base Rail
Project Type: Bespoke Metrology System
Industry: Precision Measurement
Part: Guide Rail & Electronic Housing Components
Service Provided: Vantis DFM & Machining
The Challenge
Our customer came to us with an ambitious request: produce a bespoke guide rail over a metre in length, designed to retrofit a SIP metrology machine. They were adapting a high-precision metrology apparatus for their end customer — but had hit a wall.
The tool steel originally specified was only available in shorter lengths, meaning they’d have to machine and assemble multiple rails — not ideal for cost, lead time, or accuracy.
On top of that, the design wasn’t finalised. Suppliers were reluctant to take it on. They needed a partner willing to get hands-on with the engineering.
The Vantis DFM Solution
We reviewed the design through our Vantis DFM process and quickly identified a better approach.
- Material Swap: We proposed a cast iron alternative — not only more stable, but readily available in longer lengths, easier to machine, and significantly cheaper.
- Design Tweaks: We recommended increasing the number of tooling holes to improve assembly accuracy and reduce setup time.
- Manufacturing Setup: One solid rail also allowed us to simplify workholding and eliminate a host of secondary operations.
After a design review session, the customer gave us the green light to manufacture the improved version.
The Result
By switching materials and simplifying the process, we delivered a 35% cost saving versus their original design approach — and improved performance too, thanks to the one-piece base rail.
The customer was delighted.
“Honestly, I didn’t think we could change much — but the Vantis team found simple changes that saved us real money. I wouldn’t have known where to start.”
Key DFM Wins:
- Material Selection
- Workholding Simplification
- Secondary Ops Eliminated
- Lead Time Reduced
- Overall Cost Saving: 35%