$25,000+
Annual Cost Saved
2.4×
Strength Increase
21 in-lbs
Failure Load
A medical service provider was spending approximately $25,000 per year replacing repeatedly failing components inside an adjustable fixture assembly. The source of failure was traced to cast aluminum inserts that fractured under normal tightening loads. Design Iterative Analysis evaluated the failure mode, identified the weak link, and recommended a more durable replacement strategy — with the potential to eliminate a five-figure annual expense.
The aluminum inserts consistently failed in service under normal use.
New parts had to be continually purchased and stocked, adding up month after month.
Failures created unnecessary maintenance events and preventable interruptions for technicians.
The issue was not one catastrophic failure. It was death by repetition.
Mechanical analysis identified localized stress concentration at the sharp tooth geometry of the cast inserts. The parts were vulnerable at approximately 21 in-lbs of rotational load — a level easily reached with standard hand tools.
Our recommendation is to replace the cast aluminum with a machined billet component. The table below outlines the most viable material options evaluated.
| Material | Key Feature | Strength vs. Cast Al. | Cost vs. Cast Al. | Ranking |
|---|---|---|---|---|
| Carbon Steel | Low Cost | 2.8× | 1.3–1.8× | 2 |
| 316 Stainless Steel | Corrosion Resistance | 2.4× | 1.8–2.8× | 1 ★ |
| Titanium | Strength + Corrosion Resistance | 4.2× | 5–8× | 3 |
| Inconel | Heat + Strength + Corrosion Resistance | 5.0× | 10–15× | 4 |
Recommendation: Machine the insert out of 316 Stainless Steel — the best balance of durability, corrosion resistance, and lifecycle cost.
A relatively small engineering decision had the potential to eliminate a five-figure annual expense. If a part keeps failing, costing money, or slowing production — every month it continues is money you never get back.
Got a recurring failure that's costing you?