When sourcing stamped components, most buyers focus on one thing: unit price. But the lowest quote often hides costs that show up later — in tooling, scrap, inspection, or secondary operations. The result? Programs that look good on paper but bleed margin over time. 

At Integrity Manufacturing — now part of the Calisota Parts platform — we’ve seen it firsthand. With over 50 years of experience supporting aerospace, automotive, defense, electronics, and medical programs, we know that true value comes from looking deeper than the number on a quote sheet.

Here are the two biggest areas where buyers unknowingly overspend — and how to avoid it.

 

1. The Hidden Cost Drivers in Metal Stamping

Every stamped part carries costs that don’t always show up in the initial quote. The most important drivers include:

• Material utilization – Scrap is one of the largest hidden costs. A redesign that improves yield by even 5% can save tens of thousands of dollars in a medium-to-large program.
• Tooling strategy – Progressive dies cost more up front, but often reduce cycle time and lower long-term per-part costs. Compound dies may be cheaper initially, but can cost more over the life of the program.
• Tolerance levels – Specifying ±0.001″ when ±0.005″ will add die complexity, extend inspection time, and inflate costs unnecessarily.
• Secondary operations – Steps like deburring, passivating, or plating are sometimes avoidable. Smarter die design can eliminate them altogether.

💡 Buyer takeaway: Don’t stop at piece price. Ask your supplier how they’re balancing material yield, tooling approach, and cycle efficiency for your specific volumes.

 

2. Design for Manufacturability (DFM): The Silent ROI Multiplier

One of the fastest ways buyers overpay is by treating design as “finished” before involving their stamping partner. Drawings that look fine on CAD often introduce hidden costs in production. 

A short DFM review can eliminate these risks:

• Radii and bends – Sharp corners require special tooling; slightly larger radii can be produced with standard dies.
• Hole placement – Holes too close to an edge risk distortion and scrap. Moving them fractions of an inch stabilizes production.
• Feature complexity – Each emboss, tab, or louver adds another die station. Simplify features to speed production and reduce tooling cost.
• Finish expectations – Calling for “no burrs” or “mirror finish” when not functionally required increases inspection and finishing costs.
• Part consolidation – Multiple parts can sometimes be redesigned into one progressive die, eliminating assembly steps.
• Tolerance stack-up – Overly tight tolerances across parts in an assembly compound costs. Coordinating tolerances avoids over-engineering.

💡 Buyer takeaway: Involve your stamping partner early. A 30-minute DFM session before tooling is cut can save weeks of lead time and tens of thousands in unnecessary cost.

 

Why This Matters

For buyers, the real job isn’t just purchasing parts — it’s managing total program success. That means balancing cost, performance, risk, and speed to market. The best stamping partners don’t just run presses — they help you make smarter design and sourcing decisions.

At Integrity Manufacturing and Calisota Parts, we’ve helped customers:

• Save six figures annually by improving material utilization
• Eliminate finishing operations through smarter die design
• Consolidate parts to reduce assembly labor and risk
• Meet Tier 1 and government contract requirements reliably for over 70 years

 

The Bottom Line

Most buyers overpay for stamped parts because they’re focused on the wrong number. The real cost comes from design decisions, tooling strategy, and manufacturability. Choosing a partner who addresses these issues early can transform stamping from a cost center into a competitive advantage.

👉 Ready to see how DFM and cost transparency can reduce your total stamping costs?  Contact us today to start the conversation or request a quote.

As trade policies, tariffs, and global manufacturing costs continue to shift, many businesses are rethinking where and how they produce goods. Onshoring, reshoring, and strategic outsourcing are key moves to build stronger, more resilient supply chains. Companies can navigate these changes, optimize operations, and turn today’s trade changes into tangible business advantages.

Many companies are accelerating plans to manufacture onshore in the US. They want greater control, reduced lead times, and better protection against global disruptions. Onshoring and reshoring have become practical strategies to lower risk, manage costs, and improve overall supply chain resilience. Finding a trusted domestic partner like Integrity Manufacturing is critical for businesses considering these moves.

 

Experience Matters

With manufacturing shifts, experience makes all the difference. Integrity Manufacturing brings over 50 years of proven expertise in precision metal stamping, assemblies, and full project management. As a women-owned, ISO 9001:2015 certified company based in Frankfort, Illinois, we help companies streamline production confidently. Our depth of knowledge ensures strong execution and insight at every stage to support smarter, stronger operations.

 

Comprehensive Services

Integrity Manufacturing’s capabilities extend beyond metal stamping. A few examples of our services include CNC 3-5 Axis Milling, laser cutting, welding, plating, fabrication, tool room design/build, and deburring. This comprehensive suite allows clients to consolidate their manufacturing needs, ensuring consistency and efficiency throughout the production process.

 

Supporting Onshoring and Reshoring Efforts

For companies aiming to bring manufacturing to the US, Integrity Manufacturing offers several advantages:

· Quality Assurance: Our ISO certification and experienced team ensure high-quality outputs.

· Increased Speed: Centrally located in the U.S. allows quicker turnaround and shipping times.

· Cost Savings: By managing the entire production process, clients avoid the complexities and costs associated with coordinating multiple suppliers.

 

Strategic Outsourcing

Beyond onshoring, some companies may still require outsourcing to fill gaps. Integrity Manufacturing handles the details to ensure products arrive on spec, on time, and on budget every time. Our innovation and ability to handle projects from conception to completion make us a valuable partner.

 

Here for You

Integrity Manufacturing can help you and your business deliver and take advantage of these shifts.

Let’s connect to understand your manufacturing needs and where we can help: contact us or request a quote

 

Cheryl Wellman

Owner and President

Precision, innovation, and trust. These aren’t just words at Integrity Manufacturing; they are the foundation of everything the company does. As industries evolve and demand for high-quality, American-made grows, Integrity Manufacturing rises to the opportunity with end-to-end manufacturing solutions. Led by owner and president, Cheryl Wellman, Integrity Manufacturing is shaping the future of metal stamping and assemblies with expertise, technological advancement, and a commitment to excellence.

A Seamless, End-to-End Manufacturing Partner

Based in Frankfort, Illinois, Integrity Manufacturing is a certified woman-owned business specializing in precision metal stamping and complex assemblies. Founded in 2018 by mother-daughter team Cheryl Wellman and Holly Barajas, the wider team leverages an impressive 50+ years of combined industry experience to provide seamless manufacturing solutions. Their comprehensive services include a range from project inception with R&D, tooling, material sourcing, stamping, assembly, finishing and global shipping to name a few.  Integrity Manufacturing processes enables customers to streamline production through a turnkey solution, without the complexity of managing multiple suppliers.

Continuous Innovation

Innovation is at the heart of Integrity Manufacturing. With advanced CNC 3-5 Axis Milling,  laser cutting, welding, plating, and fabrication capabilities, the company continuously invests in new technologies to enhance efficiency and quality. The research and development process ensures customers can test and refine designs before full-scale production, reducing costs while maintaining precision and quality.

Cheryl Wellman, owner and president, comments, “At Integrity Manufacturing, we believe in our customers and have built a reputation for trust, accountability, and long-term partnerships.”  The company serves a range of industries including automotive, aerospace, agriculture, appliance, electronics, packaging and medical utilities.

Looking for a trusted manufacturing partner that delivers precision and reliability? Let’s connect to look at your manufacturing needs: contact us or request a quote

 

Cheryl Wellman

Owner and President