THE TIER-1 ENGINEER PRESENTS

The Tier-1 Playbook series is a collection of concise, no-fluff design guides for manufactured parts, drawn from a lifetime of experience designing products in high-volume, high-criticality manufacturing environments across the automotive and defense sectors.Each volume follows the same proven format: practical rules, tables, and ratios with clear "why" explanations. No academic theory, no endless standards, no unnecessary bloat. Just the KISS practices that deliver first-shot approval and eliminate expensive rework under relentless production pressure.The series covers key manufacturing processes, starting with:

All of these design guides use the same battle-tested approach.
If a rule survived the crucible of high-volume and high-criticality manufacturing environments, it will serve reliably in medical devices, consumer products, industrial equipment, or any other application.The goal is simple:
Give designers, engineers, founders, and teams the guidelines to ship flawless parts without learning the hard
(and excessively expensive) way.

• ABOUT

View the Guides:

• Plastic Part Design For Injection Molding
• Metal Part Design for High Pressure Die-Casting

Designing parts for the injection molding process can be an intimidating and complex task. Years of product development experience showed how quickly a simple oversight turns into a prohibitively expensive rework. From experience designing everything from Class-A painted exteriors, structural components, multi-material overmolds, complex assemblies spanning multiple tools and materials, and more, the pattern became very clear: design errors dominate as the reason for failed products, derailed programs, and massive budget overruns.This guide is the distilled result of that experience: 99 pages of practical rules, tables, and ratios with simple explanations of why they work. No academic theory, no endless standards, no unnecessary bloat; just the design practices that consistently deliver first-shot approval and eliminate expensive rework.The goal is simple: Give designers, engineers, founders, and teams the guidelines to ship flawless parts without having to learn the hard (and excessively expensive) way. The rules in this guide were forged and tested in the crucible of high-volume manufacturing, a brutal proving ground, and became the gold standard for headache-free plastic part design. They will serve you well across every industry and application.

Designing parts for the high pressure die-casting process can be an intimidating and complex task. Years of product development experience showed how quickly a simple oversight turns into a prohibitively expensive rework. From experience designing everything from Class-A parts, structural components, brackets, housings, and complex assemblies spanning multiple tools and materials, and more, the pattern became very clear: design errors dominate as the reason for failed products, derailed programs, and massive budget overruns.This guide is the distilled result of that experience: 99 pages of practical rules, tables, and ratios with simple explanations of why they work. No academic theory, no endless standards, no unnecessary bloat; just the design practices that consistently deliver first-shot approval and eliminate expensive rework.The goal is simple: Give designers, engineers, founders, and teams the guidelines to ship flawless parts without having to learn the hard (and excessively expensive) way. The rules in this guide were forged and tested in the crucible of high-volume manufacturing, a brutal proving ground, and became the gold standard for headache-free die-cast part design. They will serve you well across every industry and application.

METAL PART DESIGN FOR ADDITIVE MANUFACTURING - LASER POWDER BED FUSIONCOMING SOON - FEBRUARY 2026

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