Breaking news: that “simple bracket” might just be the sneaky culprit derailing your whole production schedule.

Every complex assembly depends on the small stuff. That means even the most basic components, like brackets, stiffeners, or tabs, have the power to throw off your tolerances, disrupt your quality assurance (QA) process, and blow your budget. Yet time and time again, they’re the last parts to get real engineering attention.

Let’s explore why these humble components cause big problems and how precision, attention to detail, and early engineering involvement can help keep your project on track.

The Domino Effect of Overlooked Small Parts

It starts with a bracket. It’s not complicated. It’s not mission-critical. So, it gets pushed to the bottom of the bill of materials (BOM) or treated as an afterthought in your CAD model. But then…

Your first prototype doesn’t fit. A slight misalignment from poor tolerance stack-up throws off your entire subassembly.
Revisions take longer than expected. Recutting, remeasuring, and reworking your CAD design eats up time, especially when it wasn’t budgeted for.
Tooling and setup costs rise. That “easy” part now needs a special fixture or a different die, and you’re adjusting the production plan on the fly.
Regulated documentation stalls. If your part requires a First Article Inspection Report (FAIR) or a Production Part Approval Process (PPAP) submission, a delay in one component can stall the entire QA timeline.
You miss your deadline. And now your launch, install, or shipment date is sliding because of one bracket.

In short, it’s not just a bracket anymore. It’s the root cause of a cascading series of headaches across design, production, quality, and delivery. And “It’s just a bracket” becomes code for “this will cost you a day (or three) in production.”

Why It Happens: Assumptions and Oversights

Most small parts don’t cause issues because they’re complex; they cause issues because they’re ignored for too long. Here’s why that happens:

1. No Early DFM Review

Design for Manufacturability (DFM) is one of the first things to go when teams are pressed for time or treating components as “easy.” But even the simplest-looking bracket can include tight bends, sharp internal corners, or missing bend reliefs that complicate production. A quick DFM review could catch these red flags before they reach the shop floor, but often, it doesn’t happen.

2. Missing or Blanket Tolerances

It’s common to see drawings default to a blanket ±0.005” sheet metal tolerance across all dimensions, even for features that directly affect fit in a tight assembly. The problem? Some dimensions might need tighter tolerances, while others don’t. This kind of generalization can either introduce unnecessary cost or leave you with an unfit part. Both scenarios lead to rework and delays.

3. Incomplete Prints and CAD Models

We see it all the time: a bracket gets added to the BOM late, and the drawing is “good enough for now.” But vague hole locations, missing material callouts, or omitted secondary ops leave your fabricator guessing. And guessing isn’t a good strategy when you’re trying to hit deadlines.

4. Skipping Prototype Stage for Minor Parts

Major components go through multiple iterations and rigorous testing. But the smaller pieces? They’re often overlooked until they don’t work. Even simple brackets benefit from early prototyping, especially if they have tight fits, odd geometries, or regulatory documentation attached.

These early assumptions become late-stage problems. And if your metal fabricator isn’t surfacing those issues during quoting or production prep, you could be headed straight for delays, added cost, or rework.

What to Do Instead: Build a Small-Part Strategy

If you want to stop brackets and other simple parts from wrecking your timeline, the solution starts before anyone cuts metal.

1. Prioritize DFM Even For “Easy” Parts

Apply the same design-for-manufacturability rigor to every part, no matter how small. This includes bend radii, hole sizing, feature spacing, and flat pattern considerations. A knowledgeable fabrication partner like HPM can flag geometry that’s likely to warp, crack, or need post-processing with expert DFM engineering support.

2. Establish Tolerance Hierarchy

Don’t let non-critical dimensions choke your QA process. Instead, define which features are functional and where looser tolerances are acceptable. You’ll reduce unnecessary rejections and streamline first article inspection.

3. Involve QA Early (Especially For Regulated Industries)

If FAIR, PPAP, or Coordinate Measuring Machine (CMM) inspection is required, those processes must start with accurate models and well-documented specs. Catching bracket errors after inspection is complete can mean restarting the entire documentation workflow. Well-established fabrication partners like HPM can even help make these processes faster by automating FAIR documentation.

4. Prototype Everything That Touches Fit Or Function

Don’t skip prototype review just because a part looks simple. Often, it’s the interaction between “easy” parts and the rest of your assembly that causes misfits. Flat part inspection using tools like laser scanning can catch those gaps before production ramps.

The Bottom Line: Precision Starts Small

If you're trying to launch on time, meet tight specs, and avoid expensive rework, you can’t afford to ignore the details, especially when they live in the simplest parts.

Getting it right starts early. That means:

Reviewing CADs up front to catch red flags before quoting
Prototyping flat parts that affect fit, form, or function
Controlling tolerances based on actual performance requirements
Planning for documentation (like FAIR or PPAP) from the start

This kind of precision doesn’t happen by accident. It takes experience, attention to detail, and early collaboration, which is exactly what Herold Precision Metals is known for. We collaborate with teams from the very beginning to prevent the small stuff from becoming a big problem, whether you're designing medical devices, computer enclosures, or industrial assemblies. From flat pattern inspection to regulated manufacturing support, we’ve got the tools (and the team) to help you get it right the first time.

Let’s talk about your brackets, tabs, stiffeners, and everything else that keeps your assembly running smoothly.

“It’s Just a Bracket” Is Why Your Project Is Late