Air Flow Diagnostic Housing
Universal Fabrications was asked to produce a customer’s air flow diagnostic housing from three separately drawn parts. Our engineers responded with a redesigned one-piece solution that removed the weld assembly altogether. With over 45 years’ experience manufacturing welded fabrications, machined fabrications and stand-alone precision machined parts, we don’t just make what’s drawn, we look for opportunities to improve it.
The Challenge
As drawn, the housing needed three parts to be manufactured separately and then welded together. Each additional part and weld adds handling, fixturing and process time. Each additional process requires a corresponding control to ensure quality and appearance can be maintained to specification. The customer’s design worked, but it was not the most efficient way to produce the part.
Universal Fabrications’ Role
Our engineers reviewed the three-part design and developed a one-piece alternative, aluminium 6082-T6 CNC milled to precision tolerance. This removed the weld assembly operations entirely, while keeping the form and function the customer needed. All work was carried out under our ISO 9001 quality system.
Why It Mattered
The redesign delivered a 25% reduction in cost per unit. Removing the welds also improved the quality of the design, made production more efficient, and gave a cleaner, better-looking finished product. It’s a clear example of the value of design-for-manufacture input: small changes early can make a big difference to cost and quality over a production run.
Have a part that could be made more efficiently? Call 02476 370272 or email email@universalfabrications.com.
Speak to a Manufacturing Specialist today. Call 02476 370 272 or send us an email.
