DFMA Redesign to Boost Durability

I have a mature consumer product that sells steadily but doesn’t stand up to real-world abuse as well as it should. My goal is to rethink the mechanical design so the next production run is markedly tougher without driving unit cost through the roof.

Here is what I need from you: an industrial mechanical designer with at least 7–8 years on the shop-floor side of things—someone who instinctively balances DFMA principles with practical drafting skills. You will start by reviewing the current CAD set and recent failure data, then propose design changes that extend service life, reinforce high-stress areas, and simplify assembly where possible.

Key expectations
• Dive into the existing 3D model (SolidWorks, Creo, or comparable) and identify weak points through FEA or other analysis you normally trust.
• Redesign components or joints for better fatigue and impact resistance, keeping tooling changes realistic.
• Supply updated 3D files plus detailed 2D drawings complete with tolerances, material specs, and surface finishes.
• Deliver a short DFMA summary that explains how the new design improves durability while protecting margin.
• Outline any quick proto or test plan you think is essential before we cut steel.

If that sounds like your everyday groove, let’s talk timelines and get this product ready for the next level of rough handling.