Product designers with using any method available to see their project come to life. However, effective prototype development depends on factors like technology, materials, and machines. This is where DFM becomes a valuable resource in the prototyping and manufacturing process.
What is DFM?
Design for Manufacturing (DFM) is a product design method stressing the importance of prototyping parts to suit the manufacturing process. Many manufacturing companies refer to the concept as “Design for Manufacturability.”
The process consists of several design aspects, including the proposed material and shape of the product. DFM looks at the parameters involved in the production process to assess if it’s viable for production with proposed design instructions and methods.
3D printing, CNC machining, and injection molding are usually the most common methods employed in product manufacturing. DFM helps manufacturers assess production costs using these methods, serving as a reality check on what’s possible in production.
DFM gives designers ideas on how to make changes to design features that might increase production costs or slow the manufacturing process.
In some instances, DFM involves departmental collaboration or even across several companies. Engineers and designers might need to collaborate with manufacturers, toolmakers, and raw material suppliers.
Key Principles of DFM
Production Process Choice
The production process (injection molding, 3D printing, etc.) plays a role in structuring project costs. A DFM strategy should model production method alternatives across several categories and criteria.
Design Choice
Inferior design concepts cause issues with the speed of production. For example, increasing the wall thickness on injection molded parts increases cooling time.
A robust DFM strategy equips designers with the data they need to better understand the relationship between production concerns and design choices.
Tooling
A DFM strategy must include estimates for cost totals for the tooling needs of different prototypes. In some cases, it might be wise to opt for a more expensive mold to reduce costs further down the road after the prototyping phase.
Sometimes, off-the-shelf parts might suit the application better, simplifying manufacturability while leaving product function intact.
Tolerances and Specifications
DFM tooling can assist manufacturers with better accuracy in the precision optimization of product specs, functional features and requirements, and production cost targets.
The Importance of Design for Manufacturing
DFM offers the production process several benefits. Some of the reasons why it’s essential for designers and manufacturers to get on board with DFM are the following.
Increases Manufacturing Speed
DFM improves efficiency in the production process, increasing production cycle times and overall time to market for the customer.
A well-designed part ensures cutting tools and other instruments do their jobs efficiently. A basic example of DFM improving production speed is injection molding design for manufacturing.
This process involves the incorporation of draft angles into molded parts. The draft angles provide rapid ejection of molded parts. Parts without drafts require removal by force, and friction between surfaces can damage parts.
Guarantees Manufacturing Feasibility
One of the core benefits DFM offers manufacturers is a guarantee of feasibility for manufacturing and part failure prevention. DFM is critical for quality assurance. It prevents wastage and product failures, reducing costs in the prototyping stage of the development process.
Makes Automation and Simplification Possible
DFM allows designers and manufacturers the ability to create better levels of automation in the production process.
This brings a reduced need for oversight on manufacturing and reduces the need for multiple setups and machines. DFM can also identify areas where automation can save on labor costs in production processes.
Reduces Overall Project Cost
DFM creates improved efficiency in production processes while speeding up cycle times. As a result, DFM is instrumental in reducing project and prototyping costs.