In DFM, the manufacturing process is planned around the design. In this article, we will examine the big picture of DFM, the steps required for a positive outcome, some good examples of DFM, and some tips for optimising your own processes.
A part or tool can be made more efficiently and affordably through the DFM engineering practise of designing with manufacturing in mind from the start. Engineering and design teams can save time and money by using DFM to create, iterate, simplify, and optimise parts before they are manufactured.
Engineers, designers, manufacturers, material suppliers, free DFM Gerber viewer, and anyone else with a vested interest in a project’s manufacturing success are all encouraged to participate in the DFM process for the best possible results.
Let’s take a look at DFM and see how it operates and how you can optimise it.
What is the process of DFM (design for manufacturability)?
Examining these five factors—process, design, material, environment, compliance and testing—is what makes design for manufacturability (DFM) a success. As a result, designers and engineers can make components that are unique to their projects while still being simple and inexpensive to produce.
Process
The success of DFM hinges on selecting the optimal manufacturing approach for each individual endeavour. Do you need a large quantity of a specific component? You could try injection moulding as an alternative. However, 3D printing techniques like Multi Jet Fusion (MJF) and selective laser sintering (SLS) may be best suited for producing low-volume, highly detailed parts.
Considerations such as materials, part quantity, and properties of the parts or tools to be created can help you determine the best PCB manufacturing process for your needs and, in turn, reduce costs and maximise efficiency.
Design
The design of the manufactured component can begin after a manufacturing method has been selected. However, you should think about wall thickness, surface details, texture, and transitions that are specific to your manufacturing process.
It’s also worth noting that the “the simpler, the better” philosophy is central to DFM’s operations. While it’s true that not every design can be extremely straightforward, complexity typically increases production risk. The manufacturing process could ruin some designs, and others could make the price tag much higher than expected.
The success of your part also depends on your selection of a suitable design programme. If you are designing a part for sheet metal fabrication without industry-specific software, Hubs’ automated pricing could be off.
Material
Choosing the best material for your project is an important part of the manufacturing process, and you should also carefully consider the properties your part requires. The final product’s precise properties, such as heat resistance, water resistance, strength, and flexibility, will be determined by the intended use and environment.
Environment
The intended part’s design will be significantly impacted by environmental factors. Is the final product going to be put through rigors testing, as one might anticipate in a manufacturing setting? Is there a possibility of office use? It’s important to think about where and how your components will ultimately be used.
You can rest easy knowing that your product or component will last as long as possible and perform reliably in its designated setting thanks to this DFM principle.
Regulations and inspections
Your components may need to meet internal and/or external standards that are unique to your field. Your product must be in accordance with all applicable food-safety standards and regulations if, for instance, its components will be used in a setting where food is present. The DFM process should take into account all applicable standards and include preparation for testing to verify compliance.
When done correctly, DFM analysis can reduce manufacturing costs without sacrificing performance. The following will also have an impact on the DFM procedure, in addition to the five main principles:
Amount of components: There may be higher relative start-up costs associated with producing fewer parts, leading to higher unit prices. As production volume increases, per-unit costs decrease.
Complexity of the product or the design: A complex design increases the possibility of an expensive (or inefficient) manufacturing process, which is why DFM emphasises simplification.
Access to raw materials and necessary parts: How expensive and time-consuming will it be to obtain the necessary supplies? Depending on the response, the DFM procedure may change.
Modularity in design: Can you use this blueprint for different tasks? When designing, try to think in terms of modules so that different parts of the system can be reused in different projects.
Aesthetics: Does it matter if your component looks good or not? The production cost and time increase when aesthetic features like surface finishes, colour, and personalised markings are included. A product’s aesthetics should be given careful consideration before production even begins, but ideally during the design phase.
Why is DFM so advantageous, exactly?
DFM is a process that helps make custom parts more affordable, quicker to produce, and of higher quality overall. To achieve this goal, it is necessary to take measures to reduce the number of components used in the finished product, to standardise those components to ensure consistency, to create modular designs that can be used in subsequent products, to facilitate a streamlined manufacturing process, and so on.
With the help of DFM analysis, you can create a design that is perfect for mass production, which means you can save money without sacrificing quality.
In what ways can DFM best be utilised?
How well DFM serves you will be determined by the method of production you employ: Design for manufacture (DFM) for 3D printing will necessitate distinct considerations from those for CNC machining, injection moulding, or sheet metal fabrication.
Bend and fillet locations, as well as hole spacing, must often be taken into account when performing design for manufacture on sheet metal. However, using a DFM approach with 3D printing will benefit from closer examination of mechanical properties like strength and flexibility, especially when creating a part for prototyping.
It is crucial that you understand the benefits and drawbacks of your manufacturing process. DFM can be viewed as a preventative measure for avoiding costly delays and overruns. Maximising its potential requires intimate familiarity with your organization’s unique use case, application, and production procedure.
In what way does Hubs’ DFM analysis function?
To minimise expenses and production delays, the Hubs quote building platform employs in-house developed Design for Manufacturing (DFM) software to identify potential design issues in advance of production.
In this way, you know that your custom parts will always be delivered quickly and at the lowest possible cost.
