DC36 sheet-metal enclosure: up to 35% manufacturing cost reduction
A 900 VA power-unit enclosure was redesigned around sheet-metal bending, fewer separate parts, reduced welding and near-elimination of manual fitting after assembly.
Industrial problem
The enclosure measured approximately 515 × 245 × 177.5 mm. The main manufacturing losses were driven not by steel price but by the design itself: multiple separate enclosure parts, welded joints and manual adjustment after assembly.
Engineering approach
Pavel Samuta redesigned the enclosure around a base sheet-metal flat pattern. Part of the welded construction was replaced by bending, holes and slots were moved to the cutting stage before bending, and assembly references were organized so components could fit without subsequent drilling, milling or manual rework.
Reported result
The production cycle was reduced by approximately 15%, manual fitting was practically eliminated and manufacturing cost was reduced by up to 35%, depending on operation mix and batch size. Detailed ranges for part count, weld length and scenario economics are engineering estimates rather than independently audited financial results.
Business meaning
The main lesson is that manufacturing cost can be embedded in geometry long before a part reaches the shop floor. Fewer parts, fewer welds, fewer setups and more predictable assembly can create recurring savings across every production batch.
35% of the cost was not hidden in the price of steel. It was hidden in geometry decided at the CAD stage.