Material Savings for Component
Resistance Welded Assembly

Challenge: Large American automaker needed to prevent catastrophic engine failures due to oil starvation in high-speed high-G turns.

Solution: The OEM worked closely with Res to design a solution and develop prototypes to quantify the results. Res then worked closely with the OEM to develop a final design comprised of a 6-component resistance welded assembly. During the design development phase, Res offered much Design For Manufacturability input allowing the OEM to achieve a 10% material savings. Further VA/VE recommendations provided a 30% reduction in the number of welds, increasing throughput by 33% also reducing fixture costs and overall costs.

Outcome: The entirely new assembly was designed, tested and production ready within 10 months. Res currently supports the worldwide production volume for this V6 engine platform.

This is a prime example of how Res’ broad capabilities from design through start of production enabled a customer to reduce the time to market on a critical program and at the lowest possible cost.