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DFM practices have evolved over the years to keep pace with advancements in manufacturing technologies and processes. In its early stages, DFM was primarily concerned with reducing the number of parts in a product and simplifying assembly processes. This evolution has resulted in a more holistic and integrated approach to product design and manufacturing. DFM is a crucial aspect of product design, especially in today’s fast-paced world, where time-to-market is critical. By leveraging DFM, you can identify and solve potential issues early in the design process, resulting in better quality products and increased efficiency.
Assembly Capabilities
Collaborating across disciplines is a great approach to fostering a DFM mindset. When engineers and designers work together, it becomes easier for them to spot problems early on in the manufacturing process. They can share notifications with one another about product design changes that make the product more cost-effective. Staying in contact with one another throughout the entire design phase is essential to facilitating effective DFM approaches.
Advantages and Disadvantages of Design for Manufacture and Assembly
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With one click, you can launch a virtual version of the product to see if you need to make any changes. Most importantly, you can use simulation to guide your production process. Finally, a lack of resources, including time and budget, can also be an obstacle to DFM implementation. Designing products with manufacturing in mind requires additional time and resources, which may not be available in all companies.
Challenges and Considerations in Implementing DFM
DFM will allow potential problems to be fixed in the design phase which is the least expensive place to address them. Other factors may affect the manufacturability such as the type of raw material, the form of the raw material, dimensional tolerances, and secondary processing such as finishing. Design for manufacturing (DFM) is an essential aspect of product development that helps designers and engineers create simple, cost-effective products. The implementation of DFM principles means we should consider all aspects of the manufacturing process, from raw materials to final assembly, to guarantee that the product is made effectively and of good quality.
Broadening the scope of DFM becomes more accessible as manufacturing efficiency increases, allowing manufacturers to focus on other aspects of improving manufacturability. Common areas for increasing scope include product weight and dimensions, tooling, and labor costs. Optimizing these areas can also improve the organization’s overall efficiency.
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Early collaboration can significantly reduce production costs and lead times. It can also improve product quality and reliability by ensuring that the product is designed with manufacturing best practices in mind. Moreover, early collaboration fosters better communication and understanding between design and manufacturing teams, leading to more efficient and effective product development processes.
Assembly →
Meanwhile, a 100% recycled plastic part may have a lower carbon footprint, but the quality may drop, requiring a faster rate of replacement for the part. Stereolithography (SLA) and selective laser sintering (SLS) are ideal technologies for 3D printing prototypes. Professional 3D printers offer a selection of engineering materials, and produce smooth, isotropic parts that are both strong and highly detailed. SLS printers are geared more towards producing functional prototypes and production parts out of flexible or rigid thermoplastic materials such as nylon. We go into greater detail about how a comprehensive digital manufacturing simulation solution can provide in-depth manufacturing cost models faster than ever in our white paper here. The same simulation-driven tools and insights that make it possible to quickly generate process-specific manufacturability analyses are bringing unprecedented precision to manufacturing cost modeling.
Manufacturing process
The goal of design for manufacturing (DFM) is to optimize a product's design to save costs, improve efficiency, and streamline the manufacturing process. Another aspect that can have a huge impact on the final product cost is the tolerances assigned to the product. Specifying unnecessarily tight tolerances can increase the costs in the form of extra machining time or it might add the need for a secondary machining process. At times, the company may have to change the manufacturing process to meet certain specifications. The designers should set the loosest tolerances possible while meeting the functional requirements of the product. Using such tolerances reduces tooling costs and the number of defects, all while making the product easier to manufacture.
In this article, we’re focusing on DFM in the electronic manufacturing process, and specifically on DFM for printed circuit boards – PCB DFM. When using DFM principles, documentation and standardization are of the utmost importance in promoting knowledge transfer and ensuring good communication between the design and production teams. Documentation that is easy to read and comprehend lays the groundwork for cooperation and understanding by recording design intent, production needs, and important specifications. The trade-off between design complexity and manufacturability is a real concern in the realm of innovative products. When designing for simplicity rather than complexity, it is important to avoid sacrificing aesthetics or utility in favor of convenience of manufacture. Giving the client and internal teams a bird's-eye perspective of the facility floor layout, resource needs and process flow is now possible using virtual reality technology.
Calculating how these factors interact to contribute to a component’s ultimate cost structure is a very complex analytical challenge. A tweaked materials selection, for instance, may require a different manufacturing process only available at a different manufacturing facility with far higher rental and transportation costs. However vital, design for manufacturability is only one part of the puzzle when it comes to optimizing product costs and lowering the carbon footprint. Learn more about how to optimize product cost engineering for your organization. LEADRP provides prototyping and on-demand manufacturing services, including CNC machining, sheet metal fabrication, custom tooling, injection molding, urethane casting, and 3D printing. With LEADRP, you can solve any challenge throughout product development and manufacturing.
Plastics that are particularly soft and gummy may have machinability problems of their own. Lastly, the volume (number of parts to machine) plays a critical role in amortizing the set-up time, programming time and other activities into the cost of the part. In the example above, the part in quantities of 10 could cost 7–10 times the cost in quantities of 100. Each operation (flip of the part) has set-up time, machine time, time to load/unload tools, time to load/unload parts, and time to create the NC program for each operation. If a part has only 1 operation, then parts only have to be loaded/unloaded once. Reichhart Logistik understood this dynamic and used digital logistic solutions from Siemens to simulate scenarios and optimize transport networks.
To further optimize the product for sustainability, it can be simulated alongside related production systems to identify manufacturability or energy consumption improvements before making real-world investments. Accessible design exploration allows for hundreds of design options and pushes the boundaries of sustainable innovation. It can also remove time-intensive reworks, giving rise to adopting more innovative technologies and materials.
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