Vollrath Manufacturing Services White Paper
Choosing The Right Metals to Manufacture Your Product
Metal Selection in Product Development
How to Choose the Right Material for Performance and Cost
Selecting the right metal is one of the most important decisions in product development and manufacturing. With thousands of available materials and alloys, the process can become complex—especially when balancing cost, performance, manufacturability, and long-term durability.
Rather than approaching metal selection as a standalone decision, it should be evaluated within the full context of the product: its end use, manufacturing process, and performance requirements. When approached systematically, material choice becomes a structured engineering decision rather than a trial-and-error exercise.
The best material is not always the lightest or least expensive—it is the one that delivers the required performance at the lowest total cost of production.
Start with Product Objectives and End-Use Requirements
Effective material selection in engineering begins with clearly defined project objectives. Before evaluating metals, teams should establish what matters most for the product.
Key considerations include:
- Performance requirements: strength, corrosion resistance, temperature tolerance
- Cost targets: both material and total production cost
- Aesthetic needs: surface finish, appearance, and branding requirements
- Weight constraints: especially in transportation or handheld applications
Evaluating these factors at both the component and system level ensures that each material decision supports the overall function of the product.
Break the product down into individual components, evaluate their requirements separately, then reassess how they function as a complete system.
Understand How Manufacturing Processes Affect Material Performance
A common challenge in metal selection for manufacturing is evaluating materials based only on their raw properties rather than how they behave during production. Processes such as deep draw stamping, forming, or heat treatment can significantly change material characteristics.
For example, selecting a lightweight metal may seem ideal for reducing part weight. However, if the material requires increased thickness to meet strength requirements during forming, the final component may ultimately weigh more than an alternative material.
Material performance must be evaluated in its formed state, not just in its raw form. Manufacturing processes can alter strength, thickness, weight, and durability.
This reinforces the importance of aligning material selection with manufacturing process capabilities early in development.
Total Cost vs. Material Cost
Material cost is often one of the first variables considered during product design. However, lower-cost materials can introduce additional processing steps that increase total production cost.
For instance, a lower-cost metal may require coatings, finishing operations, or corrosion protection treatments that add time and expense. In contrast, a higher-grade material with inherent properties may eliminate these steps.
- Consider finishing and coating requirements
- Evaluate secondary operations and labor impact
- Factor in lifecycle performance and maintenance
- Compare total cost—not just raw material price
Focusing on total cost of ownership leads to more accurate and sustainable material decisions.
The Role of the Manufacturing Partner in Material Selection
Engaging a manufacturing partner early in the design process can significantly improve material selection outcomes. Manufacturers bring practical insight into process constraints, tooling requirements, and cost drivers that are not always visible during initial design work.
When manufacturers are involved early, they can:
- Recommend alternative materials with similar performance at lower cost
- Identify manufacturability risks before designs are finalized
- Align material selection with forming, stamping, or finishing processes
- Improve quoting accuracy and reduce redesign cycles
Early collaboration with a manufacturing partner supports design for manufacturability (DFM), reducing delays, rework, and unexpected cost increases.
“Early engagement helps ensure that material, design, and manufacturing assumptions are aligned before constraints are locked in.”
Dan Blindauer, Regional Sales Manager at Vollrath Manufacturing Services
A Structured Approach to Metal Selection
A repeatable, step-by-step approach helps organizations improve consistency and reduce risk during material selection. A typical framework includes:
- 1. Define requirements: Performance, cost, and production goals
- 2. Evaluate manufacturing processes: Forming, machining, finishing constraints
- 3. Compare material options: Properties, availability, and compatibility
- 4. Validate with a manufacturing partner: Confirm feasibility and cost assumptions
Material selection should be iterative and collaborative, with feedback loops between engineering, sourcing, and manufacturing teams.
Conclusion: Aligning Material, Design, and Manufacturing
Metal selection is not an isolated decision—it is a critical component of the broader product development process. The most effective outcomes occur when material choice is aligned with design intent, manufacturing processes, and long-term product performance.
By focusing on end-use requirements, understanding process impacts, and involving manufacturing expertise early, organizations can improve cost efficiency, reduce risk, and accelerate time to market.
Successful material selection balances performance, manufacturability, and total cost—guided by early collaboration and informed decision-making.
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