Engineering review
Drawings, load context, material choice and manufacturability are reviewed before supplier alignment.
Technical Projects and Engineering Case Studies
Review compact project examples showing how EDS supports engineering review, sourcing coordination, supplier follow-up, quality documentation and measurable industrial component outcomes.
Overview
Engineering-driven project
These cases summarize how EDS reviews technical requirements, evaluates manufacturing routes, coordinates external suppliers and follows quality and delivery expectations for industrial components.
Sourcing coordination
EDS connects technical requirements with suitable casting, forging, machining and finishing partners.
Quality and delivery control
Inspection expectations, certificates, reporting and delivery planning are coordinated through the project.
EDS Projects
Compact technical project review
Each card starts with the key technical facts. Expand a card to review the challenge, before/after context, EDS contribution, material and process details, metrics and validation notes.
Project Cases
Agricultural Machinery
Movable bracket - welded construction redesigned into ductile iron casting
A welded movable bracket was redesigned into a ductile iron sand casting to reduce fatigue-related risk, welding deformation, machining requirements and component weight.
- Component
- Movable bracket of a forage harvester
- Material
- Ductile iron
- Process
- Sand casting
Technical challenge
The original welded construction suffered from fatigue failure and deformation caused by welding. The customer needed a cost-efficient casting solution while maintaining or improving performance and meeting a demanding project deadline.
Before / after
Before: Welded construction with fatigue failure and deformation caused by welding.
After: Optimized ductile iron sand casting built into the machine within the project window.
EDS contribution
EDS supported the redesign of the welded construction into an optimized ductile iron sand casting, helping reduce weight, machining requirements and production complexity.
Material and process details
Material: Ductile iron
Process: Sand casting
Agricultural Machinery
Rear axle - welded construction redesigned into ductile iron casting
A welded rear axle construction was evaluated and redesigned as a ductile iron casting with a hollow triangular cross-section to support performance requirements.
- Component
- Rear axle of a mower conditioner
- Material
- Ductile iron
- Process
- Sand casting
Technical challenge
The customer wanted to evaluate whether a welded rear axle construction could be redesigned as a cost-efficient casting while maintaining performance and improving ground clearance.
Before / after
Before: Welded rear axle construction.
After: Ductile iron casting concept with hollow triangular cross-section.
EDS contribution
EDS supported the casting-oriented redesign and helped evaluate how the geometry could meet the relevant load cases and application requirements.
Material and process details
Material: Ductile iron
Process: Sand casting
Agricultural Machinery
Fusee - overengineered welded hub redesigned into ADI casting
An overengineered welded steering knuckle hub was redesigned into an ADI casting, integrating multiple configurations into one casting concept.
- Component
- Steering knuckle hub / fusee
- Material
- ADI
- Process
- ADI sand casting
Technical challenge
The original welded steering knuckle hub was overengineered. The customer wanted to reduce weight, production cost and assembly complexity while combining multiple components into a single casting.
Before / after
Before: Overengineered welded hub assembled from multiple elements.
After: ADI sand casting integrating three configurations into one component concept.
EDS contribution
EDS supported the redesign into an ADI sand casting, using topology optimization principles to apply material where technically needed.
Material and process details
Material: ADI
Process: ADI sand casting
Construction Equipment
Clamp housing - fatigue-resistant casting for vibratory piling equipment
A clamp housing for vibratory piling equipment was redesigned with a focus on fatigue resistance, stress optimization and usability improvements.
- Component
- Clamp housing of a vibratory piling hammer
- Material
- Cast steel
- Process
- Steel casting
Technical challenge
The original components were exposed to millions of vibrations per year and were not optimized for fatigue performance. Higher material and quality requirements increased cost without sufficiently solving the functional issue.
Before / after
Before: Original components exposed to millions of vibrations per year and not optimized for fatigue performance.
After: Cast steel redesign focused on stress distribution, fatigue-related improvement and field usability.
EDS contribution
EDS supported a new design approach focused on stress optimization, fatigue resistance and usability improvements in a cast steel component.
Material and process details
Material: Cast steel
Process: Steel casting
Agricultural Machinery
Axle bracket - detachable suspension bracket redesigned for casting
A welded rear axle suspension bracket was redesigned into a detachable casting concept to improve assembly flexibility and reduce weight.
- Component
- Rear axle suspension bracket
- Material
- Ductile iron
- Process
- Casting-oriented redesign
Technical challenge
The original suspension bracket was welded to the machine frame. The customer wanted a detachable connection so different axle systems could be used while keeping the design suitable for demanding environments.
Before / after
Before: Suspension bracket welded directly to the machine frame.
After: Detachable ductile iron casting concept allowing different axle systems.
EDS contribution
EDS supported a new assembly concept and optimized the bracket design for ductile iron casting.
Material and process details
Material: Ductile iron
Process: Casting-oriented redesign
Heavy-duty semi-trailers
Rocker arm - cost-effective ADI casting for heavy-duty semi-trailers
A heavy-duty semi-trailer rocker arm was redesigned into an ADI casting while maintaining interchangeability with the original part.
- Component
- Rocker arm
- Material
- ADI
- Process
- ADI casting
Technical challenge
The component had to perform in rough operating conditions while reducing cost compared with the welded part.
Before / after
Before: Welded part used in rough operating conditions.
After: ADI casting designed to remain interchangeable with the original component.
EDS contribution
EDS supported the redesign into an ADI casting while maintaining interchangeability with the original part.
Material and process details
Material: ADI
Process: ADI casting
Automotive
Automotive stainless steel bracket - assembly replaced by single casting
An automotive stainless steel bracket assembly was redesigned as a single casting, removing machining while reducing weight and cost.
- Component
- Stainless steel bracket
- Material
- Stainless steel
- Process
- Single casting redesign
42%Weight reduction
70%Cost reduction
Technical challenge
The original assembly required machining and offered opportunities for weight, cost and geometry improvement.
Before / after
Before: Original machined assembly with weight and cost improvement potential.
After: Fully weight-optimized stainless steel single casting.
EDS contribution
EDS supported a casting-oriented redesign that replaced the assembly with a single casting, removed machining requirements and enabled branding through the production method.
Material and process details
Material: Stainless steel
Process: Single casting redesign
Outcome metrics
- Weight reduction: 42%
- Cost reduction: 70%
Outcome highlights
- 42% weight reduction
- 70% cost reduction
- No machining required
- Assembly replaced by single casting
- Production method allows branding
Heavy-duty trailers
Lashing eye - securing heavy truck loads for heavy-duty trailers
A lashing eye for heavy-duty trailer load securing was developed around a simple bolt connection, high load capacity and low component weight.
- Component
- Lashing eye
- Material
- Metal load-securing component
- Process
- Casting / load-securing component sourcing
3.8 kgWeight after
Technical challenge
The load-securing point needed a simple bolt connection, high radial and axial load capacity and a low component weight.
Before / after
Before: Load-securing requirement for heavy truck and trailer applications.
After: Lightweight lashing eye with bolt and shackle connection interfaces.
EDS contribution
EDS supported the lashing eye concept for heavy truck load securing, combining bolt and shackle interfaces with a lightweight component design.
Material and process details
Material: Metal load-securing component
Process: Casting / load-securing component sourcing
Outcome metrics
- Weight after: 3.8 kg
Outcome highlights
- Easy bolt connection
- 15 ton radial securing load
- 6.7 ton axial securing load
- Light component weight of 3.8 kg
- M33 bolt connection and 40 mm shackle connection
Heavy-duty trailers
Trailer outrigger - side support for extending trailer loading width
A trailer outrigger side support was developed to extend trailer loading width with easy position changes, low weight and configurable sizing.
- Component
- Trailer outrigger / side support
- Material
- Steel forging and casting combination
- Process
- Forging and casting combination
4.3 kgWeight after
Technical challenge
The trailer support needed to extend loading width while remaining easy to switch between on-duty and off-duty positions.
Before / after
Before: Trailer loading-width extension requirement with on-duty and off-duty handling needs.
After: Lightweight outrigger and mount system using steel forging and casting.
EDS contribution
EDS supported a trailer outrigger concept combining a forged outrigger with cast mounts, keeping the assembly lightweight and configurable.
Material and process details
Material: Steel forging and casting combination
Process: Forging and casting combination
Outcome metrics
- Weight after: 4.3 kg
Outcome highlights
- Extends trailer loading width
- Easy to change on/off positions
- 3 ton working load
- Low combined weight of 4.3 kg
- Steel forging outrigger with cast mounts
- Different sizes available and customizable
Paper industry / large printing presses
Bearing houses - two bolted constructions redesigned into one casting concept
Two bolted bearing house constructions were redesigned into one casting concept using one pattern and different core configurations.
- Component
- Bearing houses of a large printing press
- Material
- Cast iron
- Process
- Sand casting
Technical challenge
The customer wanted to redesign an assembled product into a casting while supporting two product configurations from a single casting concept.
Before / after
Before: Two bolted constructions requiring separate assembly logic.
After: One casting concept supporting two configurations through core strategy.
EDS contribution
EDS supported the casting design approach, using one sand casting pattern and different cores to enable two configurations.
Material and process details
Material: Cast iron
Process: Sand casting
Paper industry / large printing presses
Engine brackets - welded constructions redesigned into single casting solution
Welded engine bracket constructions were redesigned into a single casting solution that could be machined into different configurations.
- Component
- Engine brackets of a large printing press
- Material
- Gray cast iron
- Process
- Sand casting
Technical challenge
The customer wanted to replace welded constructions with a cast component, reduce weight and reduce machining wherever possible. Both versions of the product also needed to be combined into a single casting concept.
Before / after
Before: Welded constructions with weight, machining and deformation concerns.
After: Single gray cast iron concept supporting different machined configurations.
EDS contribution
EDS supported the redesign toward a casting solution that could be machined in different ways to create two configurations.
Material and process details
Material: Gray cast iron
Process: Sand casting
Bike industry
Kingpin - forged strength optimisation with reduced cost
A kingpin project used forging to improve construction strength while reducing cost.
- Component
- Kingpin
- Material
- Forged steel
- Process
- Forging
36%Cost reduction
Technical challenge
The component required improved construction and strength while reducing cost.
Before / after
Before: Original construction with room for strength and cost improvement.
After: Forged construction optimized for strength and cost.
EDS contribution
EDS supported a forging-based design route to improve strength and construction efficiency.
Material and process details
Material: Forged steel
Process: Forging
Outcome metrics
- Cost reduction: 36%
Outcome highlights
- 36% cost reduction
- Strength optimisation
- Improved construction through forging
Agricultural Machinery
Tine frame - improved geometry with less machining
A tine frame project focused on improved geometry and machining reduction as part of a strength optimisation route.
- Component
- Tine frame
- Material
- Cast or forged metal component
- Process
- Strength optimisation
40%Cost reduction
Technical challenge
The original tine frame offered room for geometry improvement and machining reduction.
Before / after
Before: Original geometry with machining and cost improvement potential.
After: Improved component geometry with less machining.
EDS contribution
EDS supported the redesign toward improved geometry and reduced machining requirements.
Material and process details
Material: Cast or forged metal component
Process: Strength optimisation
Outcome metrics
- Cost reduction: 40%
Outcome highlights
- 40% cost reduction
- Less machining
- Improved geometry
Forestry machines and wood cutters
Quick coupler - less welding, lower machining and improved appearance
A quick coupler project reduced welding, weight and cost while improving assembly and visual finish.
- Component
- Quick coupler
- Material
- Ductile iron
- Process
- Casting redesign
27%Weight reduction
40%Cost reduction
Technical challenge
The original quick coupler required welding and had opportunities for weight, cost, assembly and aesthetic improvement.
Before / after
Before: Steel component with welding and machining requirements.
After: Ductile iron redesign with optimized geometry and easier assembly.
EDS contribution
EDS supported a redesign from steel toward ductile iron with a fully optimized geometry and assembly-friendly nut pocket.
Material and process details
Material: Ductile iron
Process: Casting redesign
Outcome metrics
- Weight reduction: 27%
- Cost reduction: 40%
Outcome highlights
- 27% weight reduction
- 40% cost reduction
- Less welding required
- Nut pocket for easier assembly
Automatic doors and revolving doors
Glass clamp - assembly improvement with cost and weight reduction
A glass clamp for automatic doors and revolving doors was redesigned around assembly improvement and cost and weight reduction.
- Component
- Glass clamp
- Material
- Metal assembly component
- Process
- Assembly improvement
27%Cost reduction
Technical challenge
The system component had opportunities for cost, weight and assembly improvement.
Before / after
Before: Original assembly with improvement potential.
After: Improved assembly concept with lower cost and weight.
EDS contribution
EDS supported the redesign approach to simplify the assembly and improve component efficiency.
Material and process details
Material: Metal assembly component
Process: Assembly improvement
Outcome metrics
- Cost reduction: 27%
Outcome highlights
- 27% cost reduction
- Cost and weight reduction
- Assembly improvement
Modern livestock industry equipment
Guide rail - casting-to-forging conversion for alignment and wear resistance
A guide rail was converted from casting to forging to improve tolerances, alignment, wear resistance and stress behavior.
- Component
- Guide rail
- Material
- Wear-resistant steel
- Process
- Casting to forging conversion
10%Weight reduction
15%Cost reduction
Technical challenge
The original guide rail required better geometrical tolerances, alignment and stress performance.
Before / after
Before: Cast guide rail with tolerance and alignment improvement potential.
After: Forged wear-resistant steel guide rail with improved alignment.
EDS contribution
EDS supported a conversion from casting to forging using wear-resistant steel to improve alignment and reduce stresses.
Material and process details
Material: Wear-resistant steel
Process: Casting to forging conversion
Outcome metrics
- Weight reduction: 10%
- Cost reduction: 15%
Outcome highlights
- 10% weight reduction
- 15% cost reduction
- Better geometrical tolerances
- Casting to forging conversion
Agriculture / crops
Tube T-connector - cost and machining reduction
A tube T-connector was redesigned to reduce machining and cost.
- Component
- Tube T-connector
- Material
- Metal connector
- Process
- Machining reduction
20%Cost reduction
Technical challenge
The original tube connector had opportunities to reduce machining and cost.
Before / after
Before: Original connector with machining and cost improvement potential.
After: Redesigned connector focused on machining reduction.
EDS contribution
EDS supported a redesign focused on reducing machining requirements and total cost.
Material and process details
Material: Metal connector
Process: Machining reduction
Outcome metrics
- Cost reduction: 20%
Outcome highlights
- 20% cost reduction
- Machining reduction
- Connector redesign
Industrial Machinery
Leidingsteun - cost and weight reduction through redesign and finishing options
A support bracket was redesigned through as-cast, machined and electro-galvanised stages to reduce cost and weight.
- Component
- Leidingsteun / pipe support bracket
- Material
- Metal bracket
- Process
- Redesign with machining and finishing options
26%Cost reduction
Technical challenge
The original support bracket had opportunities for cost, weight and production-route improvement.
Before / after
Before: Original support bracket with cost and weight improvement potential.
After: Redesigned support bracket with finishing and machining options.
EDS contribution
EDS supported redesign stages from as-cast geometry through machined and electro-galvanised finishing options.
Material and process details
Material: Metal bracket
Process: Redesign with machining and finishing options
Outcome metrics
- Cost reduction: 26%
Outcome highlights
- 26% cost reduction
- Cost and weight reduction
- As-cast, machined and electro-galvanised options
Component Examples
Simplified examples by sector
These examples show individual components EDS can support across specific industrial sectors. They are intentionally shorter than full case studies and focus on part type, material, weight, finish and application context.
Railway
Catenary railway
Catenary railway counterweight
Compact cast counterweight for railway catenary infrastructure, supplied with corrosion-protective galvanizing.
- Part type
- Counterweight
- Material
- EN-GJL-200
- Weight
- 20 kg
- Finish
- Hot-dip galvanized to EN ISO 1461, min. 85 um
Railway
Railway slide chair casting
Ductile iron railway support component where finished weight, deburring and rust protection are key supply requirements.
- Part type
- Slide chair / rail support component
- Material
- EN-GJS-500-7
- Weight
- 21.55 kg as cast / 18.65 kg finished
- Finish
- Deburred, oiled and free from rust
Railway
Catenary railway
Catenary suspension clamp body
Small ductile iron clamp component for railway catenary mounting applications with galvanized surface protection.
- Part type
- Suspension clamp body
- Material
- GJS-400-15
- Weight
- 1.03 kg
- Finish
- Hot-dip galvanized to EN ISO 1461, min. 85 um
Railway
Catenary railway
Catenary console foot casting
Galvanized ductile iron mounting base for articulated railway catenary console assemblies.
- Part type
- Console foot / mounting base
- Material
- EN-GJS-400-15
- Weight
- 2.96 kg as cast
- Finish
- Hot-dip galvanized to EN ISO 1461, min. 85 um
Railway
Catenary railway
Railway tensioning equipment support
Steel casting support component for railway tensioning equipment, prepared for outdoor infrastructure use.
- Part type
- Fixing support for tensioning equipment
- Material
- GS240 EN 10293
- Weight
- 4.25 kg
- Finish
- Hot-dip galvanized to EN ISO 1461
Oil & Gas
Oil & gas
Pump housing casting
Large ductile iron pump housing casting with DCTG11 casting tolerances and leak-test requirements after customer assembly.
- Part type
- Unmachined pump housing
- Material
- EN-GJS-400-15
- Weight
- 250 kg
- Finish
- Deburred and SA 2.5 blasted
Application references include pressure testing at 24 bar for 30 minutes after assembly.
Oil & Gas
Oil & gas
Safety housing casting
Compact ductile iron housing with DCTG11 casting tolerances, roughness control and downstream leak-test requirements.
- Part type
- Unmachined safety housing
- Material
- EN-GJS-400-15
- Weight
- 6.3 kg as cast
- Finish
- Deburred and free from rust
Application references include 12.5-37.5 um roughness and pressure testing after customer assembly.
Construction Equipment
Construction machinery
Construction machinery protective shell
Ductile iron construction machinery shell component with high-strength material and corrosion-resistant ZnNi coating.
- Part type
- Protective shell / half shell
- Material
- EN-GJS-600-3
- Weight
- 6.87 kg as cast / 5.72 kg finished
- Finish
- Electrodeposited ZnNi coating to ISO 15726
Construction Equipment
Construction machinery
Compact construction machinery shell
Smaller high-strength ductile iron shell component for construction machinery, finished with ZnNi surface protection.
- Part type
- Compact protective shell / half shell
- Material
- EN-GJS-600-3
- Weight
- 2.42 kg as cast / 1.93 kg finished
- Finish
- Electrodeposited ZnNi coating to ISO 15726
Hydraulics
Hydraulic release lever
Small cast steel hydraulic lever with machined weight control and zinc flake surface treatment.
- Part type
- Release lever
- Material
- EN-G20Mn5
- Weight
- 0.83 kg / 0.81 kg machined
- Finish
- Non-electrolytically applied zinc flake coating to EN 13858
Hydraulics
Hydraulic bearing block
Ductile iron bearing block for hydraulic equipment with controlled finished weight and primer coating requirement.
- Part type
- Bearing block
- Material
- EN-GJS-400-15
- Weight
- 11.45 kg as cast / 9.88 kg finished
- Finish
- Primed basalt grey, 80-130 um
Offshore
Offshore worm gear set
Matched offshore gear components combining a ductile iron worm wheel with a quenched and tempered steel worm shaft.
- Part type
- Worm wheel and worm shaft set
- Material
- EN-GJS-700-2 wheel / 42CrMo4+QT shaft
- Weight
- 27.191 kg wheel / 4.962 kg shaft
- Finish
- Application-specific finish to be confirmed per project
Demolition
Demolition wear tooth
Heavy-duty wear component for demolition use, heat treated for controlled hardness and supplied with basic rust protection.
- Part type
- Wear tooth
- Material
- ZG13Mn, heat treated to 179-229 HB
- Weight
- 43.5 kg
- Finish
- Deburred, oiled and free from rust
Heavy Equipment
Heavy equipment
Heavy equipment ballast counterweight
Large cast iron ballast weight for heavy equipment with coating and dimensional inspection requirements.
- Part type
- Ballast counterweight
- Material
- EN-GJL-250
- Weight
- 2820 +/- 50 kg
- Finish
- Primer and wet paint, 80-130 um
Dimensional reporting can be prepared for agreed inspection balloons per batch.
Case Structure
How EDS structures project examples
EDS project examples are reviewed internally before publication. A useful case should make the technical challenge clear, explain the material and process choice, describe the sourcing route, show quality documentation expectations, include delivery or logistics control where relevant and summarize measurable outcomes only when those values are approved for use.
- Technical challenge
- Material and process choice
- Sourcing route
- Quality documentation
- Delivery and logistics control
- Measurable outcome
Quality & Supply Control
Project control beyond the first quotation
EDS is not a foundry and does not manufacture parts in-house. Our role is to coordinate the technical and supply process: engineering review, supplier alignment, documentation checks, inspection follow-up, material certificates, measurement reports, packing requirements and logistics coordination. This gives customers one technically informed partner for sourcing and follow-up.
Contact
Discuss a technical sourcing or redesign project with EDS
Share your drawing, requirements or sourcing challenge and our team will review how EDS can support the next step.