Custom Stamped Metal Assemblies & Production Services

We manufacture multi-component stamped metal assemblies starting from individually fabricated precision metal stamped parts that hold ±0.05mm tolerances before secondary joining begins. Utilizing automated riveting and resistance welding to achieve strict structural rigidity and specified gap and flush tolerances, our industrial metal stamping assembly processes synchronize secondary operations to mitigate dimensional deviations. Fabricated within our IATF 16949 certified facility, these optimized workflows control mechanical alignment to ensure reliable integration across high-vibration EV, industrial, and medical-grade architectures.

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kravzik-stamped-metal-assemblies-parts-components

±0.05mm Stamped Assemblies

Industrial Stamping Cells

100% Joint Inspection

IATF 16949 Certified

Production-Ready Components

High-Precision Custom Metal Assembly Solutions

Kravzik engineers complex stamped metal assemblies by integrating multiple precision-stamped components through advanced secondary processes. Utilizing automated riveting, resistance spot welding, and in-die tapping, we guarantee superior structural rigidity and strict gap and flush tolerances. Our engineering focus ensures seamless metal parts assembly integration for critical applications where structural integrity and dimensional precision are non-negotiable.

Engineered for vehicle safety and motion control, our precision automotive structural brackets ensure perfect gap-and-flush alignment and high-vibration resistance across high-performance electric vehicle architectures to meet critical quality metrics.

Typical Parts:

Battery Retention Frames, Door Latches, Seat Rails, Sunroof Frames, Steering Shrouds, Pedal Supports.

Designed for heavy-duty automated systems, our industrial metal stamping assembly process combines multi-stage stampings through specialized riveting and welding to achieve maximum torsional rigidity under severe mechanical loads.

Typical Parts:

Servo Motor Housings, Chassis Slide Rails, Gearbox Brackets, Robot Arm Joints, Pump Modules.

Critical electrical switching and distribution modules featuring integrated metal stamped components and structural housings, optimized for stable conductivity and strict thermal management in high-voltage applications, such as precision copper busbar assemblies engineered to meet stringent oem requirements.

Typical Parts:

Switchgear Busbars, Circuit Breaker Frames, Contactor Contacts, Relay Base Units, Transformer Mounts.

Mil-spec compliant systems engineered for tactical reliability. Every stamped mechanical part assembly utilizes controlled secondary joining processes to meet extreme shock, vibration, and structural rigidity standards.

Typical Parts:

Tactical Radio Chassis, Rugged Sensor Mounts, Avionics Enclosures, Missile Fin Actuators, Communication Rails.

Ultra-precise diagnostic and surgical equipment modules, focusing on sterile material compatibility, smooth articulation, and the high-tolerance integration required for critical healthcare devices.

Typical Parts:

Surgical Instrument Frames, Imaging Housings, Fluid Pump Modules, Medical Bed Hinges, Ventilator Frames.

High-volume structural modules for premium appliances. We supply global manufacturers with oem metal stamping parts, prioritizing aesthetic mechanical integration through superior gap-and-flush control and durable assembly techniques.

Typical Parts:

Appliance Door Hinges, Oven Rack Slides, Vacuum Motor Mounts, Refrigerator Frame Units, Smart Lock Chassis.

Do not see your specific component here? From ultra-fine pitch microelectronic packaging layouts to high-current power grids, we provide custom progressive tool engineering for complex electronic profiles within our metal stamping products lineup. Submit your dimensional schematics for an initial DFM evaluation to align your technical requirements with our manufacturing capabilities and receive a production-ready quote.

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CRITICAL PRODUCTION RISKS

Critical Manufacturing Risks in Custom Stamped Assemblies

Producing complex stamped metal assemblies demands mastery of individual part precision and secondary joining stability. A minor shift in alignment compromises the structural safety and mechanical longevity of the entire system. We mitigate these three critical assembly risks to ensure a zero-defect, high-rigidity supply chain for your most demanding applications.

Risk #1: Cumulative Tolerance Stack-up & Alignment
When producing multi-component stamped assemblies, dimensional variations compound exponentially. Without precision-engineered fixtures and synchronized multi-stage inspection, slight component deviations lead to severe “Gap & Flush” failures, preventing final mating with critical sub-systems.

Consequence: Non-conforming dimensions, assembly line downtime, and costly manual rework.
Risk #2: Structural Weakness in Secondary Joining
The reliability of oem metal stamping parts depends on secondary joining stability. Sub-optimal parameters in resistance welding, orbital riveting, or clinch joining create microscopic structural vulnerabilities that remain undetected until subjected to operational stress or high-frequency vibration.

Consequence: Sudden mechanical failure, loosened connections, and catastrophic safety liabilities.
Risk #3: Thermal Distortion & Mechanical Stress
Secondary operations like spot welding and high-speed tapping introduce localized heat and mechanical force that warp precision-stamped components. This internal stress induces twisting or bowing, destroying the flatness required for critical mating surfaces and compromising overall structural rigidity.

Consequence: Poor sealing performance, structural deformation, and premature fatigue leading to shortened component lifespan.

Precision engineering requires more than machine capacity; it demands a technical partner capable of managing the complex manufacturing requirements. Our case studies demonstrate how we have solved critical manufacturing challenges across multiple OEM supply chains.

Tier 1 Manufacturing

Why Choose Kravzik for Stamped Assemblies?

We eliminate critical failure points in structural integration through predictive assembly engineering. By synergizing precision multi-part stamping with automated joining technologies under strict IATF 16949 governance, Kravzik delivers absolute structural stability, perfect gap-and-flush alignment, and optimized one-stop metal assemblies engineered for high-vibration architectures.

Precision Fixturing & Synchronized Control
To eliminate cumulative tolerance stack-up, we utilize custom-engineered assembly fixtures and multi-sensor monitoring. By controlling component alignment at every stage, we guarantee that complex structural modules meet the most rigorous dimensional specifications for flawless integration.

Zero-Deviation Alignment: Eliminates cumulative errors in multi-component positioning.
Active Gap & Flush Control: Ensures flawless fit for high-precision housings.
High-Strength Joining & Automated Welding
We ensure maximum structural rigidity through precision-controlled resistance spot welding and automated orbital riveting. Our joining processes are calibrated to deliver deep penetration and consistent force, creating bonds that withstand extreme vibration and mechanical loads.

Parameter-Locked Welding: Delivers consistent structural integrity without material fatigue.
High-Load Fastening: Provides vibration-resistant integrity for critical safety components.
Integrated In-Die Tapping & Processing
Our facility features high-speed in-die tapping and automated secondary modules to maintain geometric consistency across complex parts. By integrating threading within the production cycle, we minimize part handling and preserve the physical integrity of the stamped assembly.

Precision Threading: Maintains perfect concentricity and load-bearing strength.
Automated Integration: Streamlines manufacturing for repeatable accuracy and zero handling damage.
FEA Structural Analysis & DFM Optimization
Before mass production, we perform Finite Element Analysis (FEA) and comprehensive dfm analysis for metal assemblies to identify assembly bottlenecks. We optimize component geometry to ensure your final product exceeds performance requirements for stress distribution and operational longevity.

Structural Simulation: Predicts mechanical behavior under real-world loads.
Assembly Optimization: Refines part designs for rapid, error-free manufacturing cycles.

PRECISION ALLOY MATRIX

Advanced Material Solutions for Precision Assemblies

The structural integrity of your stamped assemblies depends on precise material science. We process high-strength alloys and aerospace-grade metals to ensure optimal rigidity, weldability, and corrosion resistance. From stainless steel housings to high-yield carbon steel components, we align material properties with your specific assembly requirements to ensure peak operational reliability.

HSLA Steel (High-Strength Low-Alloy)
STRUCTURAL RIGIDITY STANDARD
Provides superior yield-to-tensile ratios for safety-critical modules. Our HSLA stamped metal assemblies offer excellent cold-forming properties and reliable compatibility with automated resistance spot welding for high-rigidity structural needs.

01. Yield & Tensile Strength
Exceptional yield-to-tensile ratio for maximum impact resistance in safety-critical modules.
02. Corrosion Resistance
Optimized for KTL and powder coating adhesion to ensure long-term environmental durability.
03. Formability & Weldability
Excellent heat-treatment response for maintaining complex geometries in latch and clip assemblies.
304 / 316 Stainless Steel
HYGIENIC & DURABLE EXCELLENCE
Maintains load-bearing capacity and oxidation resistance for assemblies in extreme industrial environments. It is the premier choice for precision metal stamped parts requiring high-integrity TIG or laser welding for sealed, sterile modules.

01. Yield & Tensile Strength
Maintains high mechanical load-bearing capacity at both cryogenic and elevated temperatures.
02. Corrosion Resistance
ltimate protection against oxidation, sterilization chemicals, and harsh industrial atmospheres.
03. Formability & Weldability
Superior deep-drawing capabilities and high-integrity TIG/Laser welding performance for sealed assemblies.
6061 / 7075 Aluminum Alloy
LIGHTWEIGHT AEROSPACE PERFORMANCE
Premier strength-to-weight ratio for flight-critical and mobile structural assemblies. These alloys support precision grain structures ideal for complex routing and reliable orbital riveting in weight-sensitive stamped mechanical part assemblies.

01. Yield & Tensile Strength
Premier strength-to-weight ratio designed for flight-critical and mobile structural components.
02. Corrosion Resistance
High natural atmospheric protection; perfectly suited for hard-anodizing and chromate conversion.
03. Formability & Weldability
Precision-controlled grain structure for multi-axis structural routing and reliable orbital riveting.
SK5 / C67S Spring Steel
MECHANICAL KINETIC RELIABILITY
Engineered for superior elastic limits in high-cycle latch and clip assemblies. It delivers consistent heat-treatment response and is fully compatible with zinc-nickel plating, making it essential for custom stamped metal parts under high mechanical stress.

01. Yield & Tensile Strength
Superior elastic limit; engineered to survive millions of cycles without permanent deformation.
02. Corrosion Resistance
Compatible with advanced zinc-nickel plating to prevent hydrogen embrittlement and surface rust.
03. Formability & Weldability
Excellent heat-treatment response for maintaining complex geometries in latch and clip assemblies.
Phosphor Bronze (C5191 / C5210)
PRECISION CONDUCTIVE FLEXIBILITY
Offers exceptional fatigue and stress corrosion resistance for repetitive mechanical and electrical contacts. Its high stamping precision supports ultra-thin profiles for industrial metal stamping assembly applications requiring reliable conductivity.

01. Yield & Tensile Strength
High fatigue resistance; ideal for assemblies requiring repetitive mechanical and electrical contact.
02. Corrosion Resistance
Exceptional resistance to stress corrosion cracking and localized atmospheric oxidation.
03. Formability & Weldability
High stamping precision for ultra-thin profiles; excellent for precision soldering and brazing.
SECC / SGCC (Galvanized Steel)
COST-EFFECTIVE SHIELDING
Provides sacrificial corrosion protection for large-scale chassis and enclosure modules. Its consistent surface lubricity ensures seamless high-volume automated assembly and riveting cycles, ideal for cost-effective oem metal stamping parts.

01. Yield & Tensile Strength
Reliable structural load-bearing capacity for large-scale chassis and enclosure modules.
02. Corrosion Resistance
Integral zinc-coating provides sacrificial protection even at sheared edges and punched holes.
03. Formability & Weldability
Consistent surface lubricity for high-volume automated assembly and riveting cycles.

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MANUFACTURING CAPABILITIES

From individual precision metal stamped parts to complex, multi-component stamped metal assemblies, we unify tooling, high-speed stamping, and secondary joining under one roof. Our integrated workflows maximize production efficiency and eliminate supplier fragmentation for Tier 1 OEMs. Our high-speed progressive die stamping lines produce individual stamped components with consistent dimensional accuracy across millions of production cycles, creating a stable baseline for precision assembly.

We eliminate secondary handling deviations by integrating complex joining features directly within the stamping cycle or via automated secondary lines. Our production cells are engineered to maintain critical dimensions across millions of cycles, ensuring high repeatability for structural modules.

Automated Joining: Parameter-locked resistance spot welding, automated robotic assembly, and secondary semi-automated lines.

In-Die Automation: High-speed in-die tapping, multi-stage threading, staking, and automated hardware insertion.

Mechanical Interlocking: Orbital riveting, clinch joining, tox locking, stacked laminations, and structural staking.

Stamping Geometry Capabilities: Fine coining, tip coin profiling, countersunk holes, compliant pin (eye-of-the-needle) geometric forming, skiving, and precision embossing.

To safeguard assemblies against environmental corrosion, galvanic degradation, and hydrogen embrittlement, we provide comprehensive industrial surface finishing and post-manufacturing treatments. Every batch undergoes strict quality controls to guarantee uniform adhesion and dimensional stability.

Pre & Post-Plating Lines: Reel-to-reel plating, selective spot plating, barrel and rack plating utilizing copper, nickel, pure tin, tin-lead, silver, gold, and zinc finishes.

Protective Surface Coatings: Electrostatic powder coatings (epoxy, nylon, PVC, polyester, polyurethane), e-coating (KTL), vinyl plastisol liquid dipping, and specialized anti-corrosion geomet coatings.

Mechanical Conditioning: High-cleanliness washing/degreasing, automated deburring, vibratory deflashing, brushing (hairline finish), and micro-polishing.

Metallurgical Enhancement: Controlled atmosphere heat treatment, carburizing, nitriding, and precision stress-relieving.

True multi-component stamped assemblies often require the faultless joining of dissimilar metals, engineered plastics, or specialized fasteners. Our automated hardware insertion cells are fully synchronized to feed and seat standard and custom components without fracturing the parent metal grid.

Mechanical Fasteners: Precision nuts, threaded studs, engineered fasteners, bushings, and custom screw machine parts.

Precision Inserts: High-retention pemserts, self-clinching inserts, metal inserts, and conductive pins.

Hybrid Substrates: Seamless overmolding and insert molding integration, combining stamped profiles with custom plastic pieces and localized insulation modules.

PRODUCT APPLICATIONS

Access expert technical guidance to optimize your component designs and resolve manufacturing challenges. Our engineering resources cover critical material selection, tolerance control, and failure prevention to ensure reliable performance in your specific application — backed by documented case studies.

kravzik-automotive-busbar-power-connectors

MANUFACTURING CAPABILITIES
Metal Stamping & Die Tooling
Engineered for high-volume reliability and critical automotive tolerances. Leveraging our ultra-precision tooling backbone—powered by simultaneous CNC, Wire EDM, and PG grinding—we build elite high-speed progressive dies and precision compound tooling to guarantee strict ±0.01mm accuracy. Our in-house tool room designs and builds custom progressive die tooling optimized for high-volume assembly production, ensuring long die life and tight tolerances. From heavy-gauge structural brackets to intricate electrical terminals & contacts, we provide a true end-to-end stamping ecosystem. Our unique integrated manufacturing advantage seamlessly bridges pure metal stamping with advanced insert molding operations under one roof, delivering a unified, single-source solution from raw alloy selection to final surface treatment.

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MANUFACTURING CAPABILITIES
Precision Metal Stamped Parts & Assemblies
Engineered for critical conductivity and uncompromising structural integrity. As an IATF 16949 certified manufacturer, we specialize in high-volume custom precision metal stamping parts that demand strict tolerances. Powered by state-of-the-art 35T and 50T precision presses and a sub-micron in-house tooling ecosystem, we expertly process high-performance copper alloys, stainless steel, and specialty metals. Our capabilities span a comprehensive portfolio, including micro-precision electrical terminals, lead frames, robust stamped metal brackets, and EMI/RFI shields. Moving beyond standard stamping parts manufacturers, we combine these stamped metal components with seamless in-house insert molding integration, delivering true one-stop, zero-defect assemblies for your most complex engineering challenges.

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TECHNICAL SUPPORT

Access expert technical guidance to optimize your component designs and resolve manufacturing challenges. Our engineering resources cover critical material selection, tolerance control, and failure prevention to ensure reliable performance in your specific application.

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Before Plating Batch: Stamped Electrical Terminals Finish Audit Checklist

A supplier who plates your terminals but skips the JESD201 post-plating anneal will pass the incoming dimensional check. You discover tin whiskers only after field returns arrive. This checklist audits plating specification, pre-treatment protocols, and post-plating verification. Go through every item.

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Before PPAP Submission: Stamped Electrical Terminals Compliance Audit Checklist

A PPAP package submitted with a compliance letter but without the Cpk capability study will pass the document checklist and fail the customer SQE review. This checklist audits dimensional capability data, material cert traceability, and testing standards documentation before the submission package leaves your supplier. Go through every document.

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Before Die Design: Stamped Electrical Terminals DFM Readiness Checklist

A terminal drawing that passes CAD review but lacks springback compensation data will drift out of tolerance by stroke 50,000. Your supplier catches it only at first-article rejection. This checklist audits flat blank layout, bend radii, and material grain alignment before die steel is cut. Go through every item.

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Before Tooling Cut: Stamped Electrical Terminals Supplier Audit Checklist

A missed JESD201 anneal on your terminal lot triggers PPAP rejection, and you catch it only at the compliance audit. This checklist verifies DFM sign-off, material certs, and compliance docs before tooling cut. Go through the full audit.

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Production-Scale Consistency: Appliances Stamped Electrical Terminals Engineering Guide

A washing machine control board terminal passing factory testing fails after 2,000 cycles when the crimp joint relaxes. In this guide, you will learn cost-optimized material selection and UL 60335 compliance. Read the full guide.

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USCAR-Validated: Automotive Stamped Electrical Terminals Engineering Guide

An ECU stamped terminal passing testing at 25°C fails after 1,000 thermal shock cycles from -40°C to +125°C. In this guide, you will learn USCAR-2 contact stability and IATF 16949 PPAP. Read the full guide.

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SERVICES LIBRARY

Explore Other Stamped Parts Available

Lead Frame

Kravzik is an IATF 16949 certified lead frame manufacturer. We deliver high precision stamped lead frames and custom leadframe components with sub-micron pitch accuracy for dense IC packaging.

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Stamped Brackets

High-volume custom metal brackets stamping. Strict ±0.05mm stamped precision with 500T+ capacity. IATF 16949 certified with zero-defect consistency. Visit more!

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Eyelet Wire Connector

Stop high-voltage terminal overheating and mechanical crimp failures. We guarantee

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Stamped Electrical Terminals

Kravzik manufactures custom stamped electrical terminals from high-conductivity copper and bronze alloys. IATF 16949 certified & ±0.01mm precision. View More!

Learn More

Request DFM EvaluationView Stamped Parts Center

TECHNICAL REFERENCE

Answers to common questions regarding precision, tooling, materials, and our integrated molding capabilities.

How do you ensure precise Gap and Flush assembly tolerances?

We utilize custom-designed precision fixtures and automated sensor monitoring to align components during the joining process. By controlling individual part dimensions and synchronizing the assembly sequence, we minimize cumulative errors to meet strict OEM specifications.

What secondary joining processes are available for complex metal modules?

Our facility is equipped for automated resistance spot welding, orbital riveting, clinch joining, and in-die tapping. These integrated processes allow us to combine multiple stamped components into rigid structural assemblies with high repeatability and mechanical strength.

How do you guarantee structural rigidity for high-vibration automotive components?

We conduct Finite Element Analysis (FEA) during the design phase to identify potential stress points. By locking in specific welding and riveting parameters under IATF 16949 standards, we ensure every assembly withstands long-term mechanical stress and operational vibration.

How is cumulative tolerance stack-up managed during the assembly phase?

Our engineering team performs a thorough Tolerance Stack-up Analysis during DFM. We optimize tooling design and assembly master-points to ensure that minor variations in individual parts do not compromise the final functional dimensions of the module.

Do you perform structural integrity testing for multi-component metal assemblies?

Yes, we provide comprehensive testing including pull-force tests, torque verification, and cross-sectional weld analysis. For critical applications, we offer 100% automated vision inspection to verify that every fastener and joint meets your structural requirements.

Can your engineers assist with DFM for reducing assembly costs?

Absolutely. We specialize in optimizing part geometry to simplify secondary operations. By suggesting integrated features like self-locating tabs or reducing the number of required fasteners, we help clients lower production costs while improving assembly reliability.

Are you capable of assembling modules using dissimilar metal materials?

Yes, we have extensive experience joining different alloys, such as copper-to-steel or aluminum-to-stainless steel. We select specialized joining techniques and surface treatments to prevent galvanic corrosion and ensure a stable mechanical bond between dissimilar materials.

What is the typical lead time for custom assembly tooling?

Tooling lead times generally range from 4 to 8 weeks depending on the complexity of the fixtures and progressive dies. We offer expedited prototyping services to validate assembly designs and structural integrity before committing to full-scale mass production.

Still have questions?

Our engineering team loves solving complex problems. Chat with us or send your drawing for a review.

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Custom Stamped Metal Assemblies & Production Services

High-Precision Custom Metal Assembly Solutions

Automotive & EV

Typical Parts:

Industrial Machinery

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Power & Energy

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Defense & Aerospace

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Medical Devices

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Consumer Goods

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Critical Manufacturing Risks in Custom Stamped Assemblies

Risk #1: Cumulative Tolerance Stack-up & Alignment

Risk #2: Structural Weakness in Secondary Joining

Risk #3: Thermal Distortion & Mechanical Stress

Why Choose Kravzik for Stamped Assemblies?

Precision Fixturing & Synchronized Control

High-Strength Joining & Automated Welding

Integrated In-Die Tapping & Processing

FEA Structural Analysis & DFM Optimization

Advanced Material Solutions for Precision Assemblies

HSLA Steel (High-Strength Low-Alloy)

304 / 316 Stainless Steel

6061 / 7075 Aluminum Alloy

SK5 / C67S Spring Steel

Phosphor Bronze (C5191 / C5210)

SECC / SGCC (Galvanized Steel)

Integrated Manufacturing Capabilities

In-Die & Secondary Assembly Processes

Post-Stamping Surface Treatments & Coatings

Integrated Hardware & Mating Components

Industries Served

EV Metal Stampings

Plastic-Metal Stampings

Solar

Logistics

Semiconductors

Medical

Consumer Electronics

Aerospace

Energy

Defense

Metal Stamping & Die Tooling

Precision Metal Stamped Parts & Assemblies

Engineering Solutions & Design Insights

Before Plating Batch: Stamped Electrical Terminals Finish Audit Checklist

Before PPAP Submission: Stamped Electrical Terminals Compliance Audit Checklist

Before Die Design: Stamped Electrical Terminals DFM Readiness Checklist

Before Tooling Cut: Stamped Electrical Terminals Supplier Audit Checklist

Production-Scale Consistency: Appliances Stamped Electrical Terminals Engineering Guide

USCAR-Validated: Automotive Stamped Electrical Terminals Engineering Guide

Explore Other Stamped Parts Available

Lead Frame

Stamped Brackets

Eyelet Wire Connector

Stamped Electrical Terminals

Frequently Asked Questions

How do you ensure precise Gap and Flush assembly tolerances?

What secondary joining processes are available for complex metal modules?

How do you guarantee structural rigidity for high-vibration automotive components?

How is cumulative tolerance stack-up managed during the assembly phase?

Do you perform structural integrity testing for multi-component metal assemblies?

Can your engineers assist with DFM for reducing assembly costs?

Are you capable of assembling modules using dissimilar metal materials?

What is the typical lead time for custom assembly tooling?

Still have questions?

Request DFM & Quote