Can you perhaps elaborate how you ended up in this situation with all kinds of parts tooled but before finalising the design? Perhaps we can learn from the situation.
Ah, I thought I explained this earlier, but looks like not.
We have an existing product line (in production for about 2 years) which uses this housing and metal hardware. For this customer, we estimated that re-using the existing tooled hardware would be sufficient, since the power level is similar. However, it turns out that
this power supply runs a little hotter on top of our customer being much more stringent (than most) on this specification
It was a gamble. Half the reason the customer chose us is because we hardly had any tooling costs in our quote. Unfortunately, did not have a say in that process. And now we are struggling to make this work.