Reducing Import Costs with Reverse Engineering
- 1000+ parts optimized and manufactured
- 82% cost reduction
Background
A US-based manufacturer faced rising operational costs due to a steep 145% tariff on Chinese imports for critical components used in plastic welding machines. With only physical samples and no design files available, they needed a reliable partner to help relocate production to India while ensuring quality and engineering standards.
Challenge
1) No CAD drawings or technical specs, only physical parts
2) Needed rapid localization to India without compromising quality
3) Required parts to meet global engineering and durability standards
4) Existing operations were already stretched, needed a hands-off solution
5) High urgency due to cost pressures and supply chain risk
Solution
We acted as a full-scope engineering and delivery partner, handling the project end to end:
1) Reverse engineered critical components from scratch
2) Performed material testing and structural validation
3) Created precise 3D models and 2D drawings to global standards
4) Managed design, development, prototyping, and vendor coordination in-house
5) Collaborated with a network of 5+ trusted Indian vendors for production
6) Delivered a turnkey solution, lifting operational burden from the client
Impact
Our end-to-end reverse engineering solution delivered massive cost savings, faster execution, and long-term value for the client.
| Country | Tariff | Unit Price | Quantity | Total Value | Total Duty |
|---|---|---|---|---|---|
| 🇨🇳 China | 145% | $12 | 1000 units | $12,000 | $17,400 |
| 🇮🇳 India | 26% | $12 | 1000 units | $12,000 | $3,120 |
82% reduction in tariff costs (from $17,400 to $3,120)
$14,280 saved on just 1,000 units
5x faster turnaround via our vendor network
100% design ownership handed over for future scalability
2x increase in project volume from the same client
This project proved that with the right engineering partner, complex localization and cost challenges can be turned into long-term competitive advantages.
