Design Review
Design Review for Precision Stamped Component Programs
A design review is a pre-tooling engineering evaluation that examines whether a component design is compatible with the target manufacturing process at the required quality level and production volume. The purpose is to surface issues in geometry, tolerancing, or material specification while the design is still cost-effective to modify - before progressive tooling is built, CNC programs are developed, and fixturing is committed.
At Brunk, design reviews are conducted by applications engineers with direct knowledge of the processes being targeted. Findings are documented and returned to the customer’s engineering team with specific, actionable recommendations rather than general feedback. Our review is scoped to the actual production method. What is flagged in a review for a high-volume progressive stamping program differs from what matters for a laser-welded implantable assembly, and Brunk’s reviews reflect that specificity.
What a Design Review Examines
Geometry and feature producibility. For components intended for progressive stamping, the review examines bend radii relative to material thickness, minimum hole diameters and their relationship to stock thickness, hole-to-edge and hole-to-hole distances, web widths between features, and the overall strip geometry that determines how the part will be carried through the die. Features that would require non-standard tooling geometry, create structural weakness in the die, or compromise strip integrity under high-speed press conditions are identified and alternatives are proposed.
For CNC machined components, geometry is assessed for tool access, fixturing requirements, and the datum structure that will govern in-process and final inspection. Deep pockets, thin walls, undercuts, and feature sequences that would require multiple setups are evaluated for their effect on cycle time and dimensional stability.
Tolerance analysis. Tolerances are reviewed against the statistical process capability achievable within Brunk’s production environment. A tolerance that is achievable on a prototype machined part may not be producible at Cp ≥ 1.33 in a high-volume stamping process. Where tolerances are tighter than process capability supports, Brunk engineers will discuss whether the tolerance is functionally necessary or whether it can be relaxed, and what process controls would be required if it cannot. Tolerance stack-up across assembled components is also evaluated where assembly drawings are provided.
Material selection. Material choices are reviewed for compatibility with the manufacturing process, the required joining operations, and the regulatory or application environment. For medical device components, this includes evaluating biocompatibility requirements, corrosion resistance in the intended use environment, and compatibility with sterilization processes. For high-tech applications, it includes electrical and thermal properties, plating adhesion, and behavior under the process conditions used in downstream assembly. Brunk works with stainless steel, titanium, nitinol, niobium, platinum iridium, beryllium copper, and a range of nickel-based alloys, and can advise on material substitutions where the specified material creates unnecessary manufacturing complexity.
Output of a Design Review
The output of a Brunk design review is a documented set of findings organized by priority; issues that would prevent the part from being manufactured to print, issues that would create significant cost or yield risk, and observations that represent optimization opportunities. Each finding includes the specific feature or specification at issue, the reason it creates a manufacturing concern, and Brunk’s recommended modification. Where multiple solutions exist, the tradeoffs between them are explained.
This documentation becomes part of the program record and feeds directly into how Brunk structures the prototype phase and builds production tooling. Customers who proceed to tooling after a design review enter that phase with a resolved DFM baseline, which reduces the likelihood of tooling rework or design changes after first-article inspection.
Request a Design Review
Send your component drawings or CAD files to Brunk’s applications engineering team for a documented design review against your target production process.
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