The challenge began when we received a sample from a customer to reverse-engineer. The original design was meant for plastic injection moulding, ideal for high-volume production. However, for this pilot project, the required quantity was minimal—too minimal for the economics of injection moulding to work in our favour. The first quote we received floored us: ten times our budget. It was a moment that many in the industry know too well—a sharp intake of breath, followed by, "There’s no way we can make this work." But I love a good challenge.

In my decade-long career, I’ve learned that when the obvious path isn’t feasible, you start carving a new one. We began exploring:

• Alternate Manufacturing Processes: Every process, from vacuum casting to CNC machining, was put under scrutiny.

• Material Substitutes: We weighed the pros and cons of different materials, balancing cost, performance, and quality.

Each step was a learning curve, reminding me why engineering is as much about creativity as it is about precision.

Finding a solution wasn’t just about technical acumen. It required negotiation—lots of it. Reaching out to vendors, discussing possibilities, and revisiting cost structures turned into a dance of give-and-take. My years in tool rooms, supply chain management, and procurement negotiations proved invaluable here. Eventually, I found a vendor whose process innovation and pricing aligned with our budget. After a site visit to evaluate their capabilities, I felt confident we were on the right path.

This wasn’t just a project. It was a reminder that:

• Engineering is Fluid: : It’s not about rigidly sticking to the first solution. The best engineers adapt.

• Collaboration is Key: Building strong relationships with vendors and colleagues unlocks doors you didn’t know existed.

• Never Stop Questioning: Asking “what if” often leads to breakthroughs.