THE COST CHALLENGEEvery Dollar on Your BOM Multiplies at Scale
At 100 units, a $5 component choice barely matters. At 10,000 units, it is $50,000. At 100,000 units, it defines your margin. We work with teams who have a working product and need to bring the per-unit cost down for volume production. The savings come from engineering analysis, creative component selection, and practical manufacturing improvements.
WHERE THE SAVINGS COME FROM
Five Proven Cost Reduction Strategies
Component Consolidation
We look for opportunities to combine multiple discrete components into fewer, more integrated ICs. A common example: replacing separate voltage regulators, op-amps, and logic gates with a single microcontroller that handles all three functions. This reduces component count, assembly time, and board space.
Typical savings: 15 to 25% of BOM
Multi-Source Strategy
Single-source components are both a cost and supply chain risk. We identify alternative components that are pin-compatible or functionally equivalent, giving you an edge in supplier negotiations and protection against shortages.
Typical savings: 10 to 15% through competitive sourcing
PCB Optimization
We reduce board layer count where possible, optimize panel utilization, and shrink board dimensions. Moving from a 6-layer to a 4-layer PCB or reducing board size by 20% can have a significant impact on per-unit cost at volume.
Typical savings: 20 to 40% on bare PCB cost
Assembly Cost Reduction
We eliminate through-hole components in favor of SMD, reduce the number of unique parts, standardize on common footprints, and design out manual assembly steps. Every manual operation on a production line adds cost that compounds at volume.
Typical savings: 15 to 30% on assembly
Mechanical Simplification
We consolidate enclosure parts, reduce fastener types, design snap-fit assemblies that eliminate screws, and optimize for injection molding. Fewer parts mean faster assembly, fewer SKUs to manage, and lower tooling costs.
Typical savings: 20 to 35% on mechanical BOM
WHEN TO REDESIGN
When Hardware Redesign Makes Sense
You are scaling past 1,000 units per year
At low volumes, engineering cost for redesign may exceed savings. Once you cross 1,000+ units annually, even small per-unit reductions compound into significant savings. We help you calculate the breakeven point before starting.
Your BOM has single-source components at risk
If key components are going end-of-life, facing allocation issues, or come from a single supplier, redesign is both a cost play and a risk mitigation strategy. We address both in one pass.
You are losing margin on a mature product
Products that were designed years ago often carry legacy component choices, overbuilt power supplies, or oversized PCBs. A focused redesign can recover 30 to 50% of BOM cost and restore healthy margins.
Your product was designed by a different team
When the original engineering team is no longer available, the product often contains over-engineered sections, undocumented design choices, and missed optimization opportunities. A fresh engineering review reveals these clearly.
OUR PROCESS
How We Execute a Cost Reduction Redesign
BOM and Design Audit
We analyze your current BOM line by line, review the schematic and layout, and benchmark component costs against current market pricing. You receive a detailed report showing exactly where the cost reduction opportunities are.
Redesign Proposal
We present a prioritized list of changes with estimated savings, implementation effort, and risk level for each. You choose which changes to pursue based on your timeline and risk tolerance.
Engineering Execution
We implement the approved changes, including schematic updates, PCB layout modifications, new component sourcing, and any required firmware adjustments. Every change is validated against your product specifications.
Validation and Handoff
We build prototypes of the redesigned product, run functional and compliance testing, and verify that all original specifications are met. You receive updated manufacturing files and a revised BOM with confirmed pricing.
Want to Know How Much You Can Save?
Send us your BOM and product details. We will do a preliminary cost analysis and show you where the biggest savings opportunities are, with no commitment required.
Schedule a Free Consultation