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Trustbridge

  • Redesign for Cost Reduction or Performance 

    Elevate your design—cut costs and boost performance with our expert redesign services.

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At Trustbridge, we help companies redesign existing parts and assemblies to reduce cost, improve performance, and simplify manufacturing. Whether you're looking to lower your bill of materials (BOM), optimize for a new process, reduce part count, or improve a product’s reliability and aesthetics, our engineering team delivers strategic redesigns that make a measurable impact.

We combine mechanical design expertise with deep manufacturing knowledge — so every design decision is made with the realities of cost, scalability, and sourcing in mind. The result: parts that are easier to build, cheaper to produce, and better at doing their job.

What We Offer

Cost Reduction Redesign

Slash unnecessary complexity, features, and cost.
We analyze your current parts, assemblies, and manufacturing method to identify areas for cost savings. Whether it's machining time, material waste, custom fasteners, or outdated geometry, we redesign for efficiency — without sacrificing function.

  • Replace high-cost materials with lower-cost equivalents

  • Redesign features to reduce machining or mold complexity

  • Consolidate multiple parts into a single feature

  • Swap expensive secondary ops (e.g., machining) with molded-in features or cast geometry

  • Design for volume — optimize for the quantities you're producing now and later


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Performance Enhancement Redesign

Strengthen, lighten, or refine your part’s performance.
We help clients increase part durability, strength-to-weight ratio, thermal performance, vibration resistance, or aesthetics by refining geometry, material selection, or design architecture.

  • Add ribs, gussets, or support structures for improved load-bearing

  • Transition from sheet metal to machined or molded design for tighter tolerances

  • Reduce weight for moving assemblies or handheld products

  • Improve fluid flow, cooling, or airflow with CFD-informed tweaks

  • Upgrade finishes for corrosion resistance or cosmetic appeal

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Design Conversion for Process Optimization

Adapt your design for a new manufacturing method.
Sometimes the biggest cost or performance gains come from switching how you make the part. We help you redesign parts originally made for one process (e.g., CNC machining) to be produced more efficiently via casting, molding, sheet metal, or 3D printing.

  • CNC to die casting

  • Machined enclosures to sheet metal

  • Assembled parts to injection molded components

  • High-volume machined parts to MIM

  • Low-volume molded parts to urethane casting

We ensure the part works as intended while aligning with the process's tolerances, shrinkage, draft angles, and other requirements.

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Strategic BOM Optimization

Reduce part count. Standardize components. Source smarter.
We take a step back and look at your full system or assembly. Where can you combine parts? Use off-the-shelf components? Eliminate non-critical specs? A streamlined BOM isn’t just cheaper — it’s more scalable, less risky, and easier to manage.

  • Fastener consolidation

  • Hardware standardization

  • Fewer part numbers = easier sourcing and lower MOQ

  • Modular redesigns for part reusability across SKUs


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Who Benefits from a Redesign?

 

    Redesign is a high-leverage move for:

    • Startups seeking to launch lean and hit target margins

    • Growing companies scaling production and facing rising COGS

    • OEMs with legacy products no longer cost-competitive

    • Procurement teams looking to reduce vendor lock-in or consolidate suppliers

    • Product managers tasked with improving quality or reducing warranty claims

    Whether you're reacting to price pressure or proactively increasing value, redesign is a powerful tool.

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Our Redesign Process

Project Kickoff → CAD files, physical samples, BOM, goals → Engineering review + redesign plan
Cost/Performance Audit → Material, process, and tolerance analysis → Opportunities for savings or improvement
Redesign Execution → Design intent & constraints → New CAD models, 2D drawings, and documentation
Review & Validation → Your feedback or test data → Final production-ready files
Manufacturing Handoff → Target process and suppliers → Trusted vendor match and DFM check

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