What is DFM?
Design for Manufacturing (DFM) is the practice of designing products with manufacturing in mind. Good DFM reduces costs, improves quality, and speeds up production.
10 DFM Tips
1. **Uniform Wall Thickness:** Maintain consistent wall thickness to prevent warping and sink marks.
2. **Add Draft Angles:** Include 1-3° draft on vertical walls for easy mold release.
3. **Avoid Undercuts:** Undercuts require complex tooling. Redesign to eliminate them when possible.
4. **Round Sharp Corners:** Add radii to internal corners to reduce stress concentration.
5. **Minimize Part Count:** Combine parts where possible to reduce assembly time and cost.
6. **Use Standard Hardware:** Specify standard screws, fasteners, and components.
7. **Consider Assembly:** Design parts that can only be assembled one way (poka-yoke).
8. **Material Selection:** Choose materials that balance cost, performance, and manufacturability.
9. **Tolerance Analysis:** Specify only the tolerances you actually need.
10. **Early Manufacturer Involvement:** Get DFM feedback before finalizing design.
Case Study
A recent client came to us with a product design that would have cost $45,000 in tooling. After DFM analysis, we:
- Reduced part count from 12 to 7
- Eliminated 3 undercuts
- Optimized wall thickness
Result: Tooling cost reduced to $28,000, a 38% savings.