In this case study, we show how ETMA responded to the challenge set by a multinational home-appliances manufacturer with plants across Europe: to develop and industrialise a metal assembly designed to support a temperature sensor. The objective was clear—deliver a technically robust and competitive solution, fully prepared to scale to high-volume production.
CONTEXT
The client required a solution for a new version of an assembly that integrates inside an oven: a support into which the thermometer/sensor is inserted and then secured in the appliance.
This was a stainless-steel assembly designed to operate in a high-temperature environment, where material stability and corrosion resistance are critical.
ETMA was engaged to:
- develop initial samples and validate the concept under real conditions;
- evolve the solution into a robust industrial process, focused on series production;
- ensure a competitive proposal with minimal reliance on external suppliers.
THE TECHNICAL CHALLENGE
In this project, the “challenge” was not only in the individual part — it was in the assembly and in the way everything had to fit into the final product.
We are talking about an assembly made up of three metal components:
- a screw (fastening element),
- a tube that houses the sensor,
- and a sheet-metal part (the structural component of the assembly).
Beyond the geometry and the assembly itself, there was a decisive factor: material selection. As an all-stainless-steel assembly, it was necessary to ensure a solution that maintained dimensional consistency and joint quality throughout the process, without compromising the assembly’s performance inside the oven.
The complexity lay in ensuring that the three components
- worked together as a coherent, repeatable assembly;
- could be industrialised with dimensional stability;
- maintained the function and performance defined by the client;
- and enabled a competitive manufacturing route, ready for high volumes.
There was also a critical point: the client’s design needed to be finalised with sufficient detail for serial production — and, as is common in many industrial projects, that involved clarifying geometries, tolerances and assembly conditions.
ETMA’S RESPONSE
ETMA approached the project with a focus on co-engineering and industrialisation, following a simple principle: to transform a drawing into a serial solution with predictability.
The work started with the analysis of client samples and technical documentation, followed by the development of prototypes and initial samples. Throughout the process, ETMA’s technical team identified points requiring validation and clarification — ranging from geometric details to aspects that directly influence manufacturing and assembly.
Some adjustment proposals were accepted, while others remained as originally specified by the client. The balance point was reached when both parties arrived at the same “yes”:
- yes, it can be manufactured in series with consistency;
- yes, it fulfils the function of the assembly inside the oven.
The result was a solution prepared to evolve from samples to pre-series, with the capacity to scale up to regular production.
PRODUCTION PROCESSES INVOLVED
One of the decisive advantages in this project was ETMA’s ability to respond internally to multiple requirements of the assembly, through its unique system of 10 Integrated Production Processes.
In this case, seven processes from the ETMA system were mobilised:
1) Prototypes
Development and validation of the initial samples, with technical iterations until a stable solution for industrialisation was achieved.
2) Cold Forging
Production of the screw with dimensional consistency and a production rate suitable for high-volume series, ensuring repeatability during assembly.
3) Turning
Manufacturing of the tubular component that houses the sensor, guaranteeing fit stability and repeatability of the assembly.
4) Stamping
Production of the sheet-metal component, with a focus on productivity and repeatability, aligned with a serial manufacturing logic.
Development of tooling for the stamping production process and preparation of equipment solutions related to assembly, taking into account the need for automation to achieve the required production rates.
Application of heat treatment to the assembly in order to meet the client’s requirements.
Assembly of the components and welding by electrical resistance and stamping processes, ensuring a consistent joint suitable for an industrial production environment.
RESULTS
The project progressed with validation and approval of the assembly, enabling the transition to pre-series and preparation for regular production volumes.
The client started assembling the equipment using the first units, and the project moved into an industrial stabilisation phase, with an expected annual production volume of approximately 200,000 assemblies.
A DETAIL THAT MAKES THE DIFFERENCE: PACKAGING DESIGNED FOR AUTOMATION
In high-volume projects, it is not enough to manufacture well — delivery must also be engineered.
In this case, the final packaging of the assembly became a technical requirement: the part must be packed in specific trays, with a defined orientation, to enable direct feeding into an automated production line (pick-and-place), without additional handling.
ETMA supported this development in coordination with specialised partners, ensuring that the packaging solution meets the industrial objective: consistency, correct orientation and line efficiency.
ADVANTAGES FOR THE CLIENT
This case study clearly demonstrates, in practice, the impact of working with a supplier with integrated production processes:
- Fewer interfaces and reduced risk: a single partner managing several critical stages of the assembly.
- Co-engineering from the outset: technical support to finalise details that ensure serial manufacturability.
- Genuine competitiveness: reduced reliance on external suppliers and greater control over total cost.
- Scalability with method: from validated samples to pre-series and series production with predictability.
- Automation-ready: a strong focus on integration with automated lines, including packaging requirements.
WHY ETMA IS THE RIGHT SUPPLIER
When a project involves different technologies — screws, turning, stamping, assembly and equipment support — the real difference lies in who can connect everything with fast decision-making, quality control and end-to-end responsibility.
With an integrated production process system, ETMA is able to reduce complexity, accelerate industrialisation and ensure consistency throughout the project lifecycle, from prototype to series production.
If your industry needs to develop and industrialise a metal component (or assembly) with requirements for reliability, repeatability and scalability, ETMA can support you from the early prototyping stages through to serial production, with integrated processes and continuous technical support.
Get in touch and share your challenge. Our team will assess the project and propose the most efficient route to reach series production with confidence.