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Why Revisions are Normal in the Prototyping Process

Tag Archive: Metal Industry

  1. Why Revisions are Normal in the Prototyping Process

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    Introducing a new product into the world may seem like a straightforward process, as described in our blog, “How to Get a Prototype Manufactured,” but there are many obstacles that could arise that lead to early revisions. Developing complex metal components with tight tolerances and unique applications is rarely a perfect design from the start. Refinements are expected; that’s why revisions are normal in the prototyping process.   

    During NPI, or new product introduction, thoughtful revisions in the beginning development stages help identify areas of improved performance, durability, and cost-saving measures. It’s important to pinpoint possible improvements early on to avoid premature production runs that would ultimately produce faulty parts to customer standards.

    Why revisions are normal in the prototyping process

    Why Revisions are Normal in the Prototyping Process 

    Even with a great engineered design, some insights are only visible once in the manufacturing space or in a real-world application. If the need for design modifications is caught before reaching real-time application, costs can be saved in additional production time. Possible causes for revisions could be:

    Component Optimization:

    Improvements that, when made, alter structural integrity, functionality, or overall performance for the better. 

    Manufacturability Improvements:

    Features may seem ideal on paper, but when brought into a manufacturing shop, they could be refined for faster turnaround times or cost-saving measures. Adjustments could be made to the type of welding callouts or requested hardware, all of which would not be recognized until speaking to a manufacturing professional. 

    Material Selection:

    Fabrication may suggest a cheaper metal or material thickness depending on the component’s real-world use. Some material may need testing, or more information to be provided about the type of elements the component will be up against after manufacturing. 

    Installation:

    Sometimes it is necessary to run a first article, or just one part. This ensures fittings are correct and, if assembled with other components, tests how the installation goes. This allows for more revisions to be made before running bulk productions.  

    Why Early Detection is Ideal 

    Early evaluation is crucial in identifying potential challenges or adjustments before production is full-scale. This helps avoid risks of overspending for modifications down the line. 

    Design refinements reduce variations during production, keeping the products consistent and uniform. It also contributes to improving the part’s long-term reliability, identifying which modifications could be made for precision quality and design. Most of the time, this time-consuming step alters the overall design and durability, helping with the transition between prototype to bulk production. 

    Collaboration is Key 

    Successful new product introduction (NPI) is often dependent on the communication between the design engineer and manufacturing programmer. With these two being responsible for ironing out the final touches, they must review the first article and collaborate to make sure the component functions accordingly.

     At Tedco, we work closely with customers during NPI processes to help refine designs, support manufacturability, and ensure that components transition smoothly from beginning to end.

  2. Back to Basics: How to Get a Prototype Manufactured

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    There are recurring customers who have been with us for decades and order bulk-quantity productions. There are also people brand new to the world of sheet metal fabrication who walk through TEDCO’s doors all the time.

    Back to Basics: How to Get a Prototype Manufactured Once in a while, it is best to go back to basics and explain processes that are at the very foundation of what we do, such as how to get a prototype manufactured. 

    Precision sheet metal prototyping gave TEDCO the foundation to execute the larger projects we do today. When our company was just a father, son, and a small metal shop, prototyping was all we did. 

    Prototyping is the process of quickly building a simplified version of a product to test ideas, gather feedback, and, in some cases, go back to the drawing board for revisions.

    Let’s Talk Steps 

    Preparing Your Digital Model 

    Before requesting an estimate from TEDCO, you have to create a DFM, or Design for Manufacturability. You have to ensure your design uses standard material thicknesses and consistent bend radii, as well as welding, hardware, or finishing call-outs.  Keep in mind to avoid overly complex tolerances or geometries to keep costs low. 

    Manufacturers require a 3D STEP file, DXFs, and possibly other formats, depending on the software used to read the drawing.

    Choose Your Material

    It is best to stick to standard common metal materials like Aluminum, Stainless Steel or Cold-Rolled Steel for the fastest turnaround and lowest costs. If this prototype will not make it to final production and will need alterations before signing off on larger quantities, it’s best to use thinner, less expensive materials. Also smart to choose an in-stock selection from vendors to reduce lead times. Back to Basics: How to Get a Prototype Manufactured

    Submitting Request for Quote

    Now you can email TEDCO directly, or submit on our request for quote form on the TEDCO website to get pricing and lead time before taking the next steps. If there are any further questions for our executive programmer, you can arrange a meeting to discuss the project at hand. Our experts will help you agree on materials, hardware needed, or how to save costs by eliminating certain aspects of the prototype. Coming in for a meeting also presents the opportunity to tour the shop or talk about machining needs.

    This is also the time to decide on finishing treatments such as powder coating, anodizing, or chem film applied for aesthetics or for corrosion resistance. 

    Fabrication Process 

    Once the quote is approved, the purchase order is submitted, and the due date is settled upon, it is time to get this project into fabrication. In the next few months, we will dive deeper into the fabrication steps and the machines used throughout the process. Once completed, the customer typically takes the prototype back to their team or on-site, to see if the part will work as designed. If there are any further revisions that have to be made before the part goes into production, TEDCO is here for the next round of prototyping.

  3. Navigating Tariffs in the Metal Industry

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    Navigating Tariffs in the Metal Industry 

    The constant flux of tariff regulations is causing uncertainties within the sheet metal manufacturing industry. These changes can impact businesses through increased costs and supply chain delays.

    At Tedco, we are dedicated to giving our customers access to metal supplier monthly trend reports to understand how we are navigating tariffs in the metal industry, while maintaining high-quality parts, quick lead times, and precision consistency throughout this changing landscape.

    Navigating Tariffs in the Metal Industry

     

    Why Tariff Alleviation Matters in Sheet Metal Fabrication

    Tariff mitigation affects companies heavily relying on international materials, leading to price surges and production slowdowns. While the worst-case tariff scenarios seem to have been avoided, the policies are still unstable, causing ripple effects across the global material market. 

    North American Stainless has introduced a tariff-like surcharge for May shipments, with potential fees included through July. With continued uncertainties, there are talks that other mills may follow, like Constellium, which has also implemented a tariff-related surcharge. This remains a trend to watch, as well as incentives to reshore manufacturing, which will likely increase. 

     

    Tariff Implications on Planning and Purchasing Materials

    Despite policy shifts, demand is steady for now. As expected, imported materials are becoming less attractive while companies are looking for domestic producers to help avoid fees. Many remain cautious, buying far more conservatively, stocking only what they need for in-house jobs, and rethinking their sourcing strategies. While depot inventory is thinning, perhaps an indicator of future lead-time increases. Supply chain planning and purchasing strategies remain critical.

    Metal Market Landscape as of Now*

    May 11, 2025: The administration reduced tariffs to 30% after previously increasing tariffs on international imports to as high as 145%. This means a return to slightly calmer waters. 

    Aluminum, copper, and nickel had tumbled 15-20% in the previous weeks but have now rebounded by roughly 10-15%.

    Aluminum- After plunging in early April to nearly $1.05/lb, prices have rebounded to the $1.10 range. This is due to a surge of pre-tariff Aluminum that flooded the U.S. market late last year, creating a temporary buffer that is still working its way through the system. We will see Midwest premiums creep up slowly in the coming months. 

    Nickel- Pricing is stabilizing around $7/lb; this range is now acting as the natural floor, especially as Indonesia raises royalties on nickel and tin mining. 

    Steel- Particularly for hot-rolled coil steel, prices are remaining steady at around $900/ton, showing less volatility than other metals. While carbon steel producers like Cleveland-Cliffs are taking capacity offline to remain efficient, possibly triggering a price floor in the coming months. 

    Navigating Tariffs in the Metal Industry

    *Sourced from Ryerson May 2025 Market Report

     

    Tedco’s Strategy for Managing Tariff Risks

    Our company’s approach to navigating tariffs in the metal industry is with resilience, transparency to our valued customers, and smart purchasing strategies to maintain our precision quality products, fair pricing, and efficient lead times. We plan on staying vigilant on market updates to remain ahead of the material trends and keep pricing accurate.

    We will be strategic when it comes to inventory planning, buying materials conservatively. And maintaining close relationships with our primary suppliers to ensure a transparent supply chain to reduce price spikes. 

    Tedco also sources domestically, giving us tighter control over costs, delivery, and turnaround times. 

     

    Let’s Connect 

    Want to know how Tedco can support your next project?- Contact us to learn more about our approach to risk management, precision fabrication, and how we are navigating tariffs in the metal industry. 

    More on current tariff conditions here.