When creating a new product, it’s tempting to focus solely on design and function. But incorporating manufacturability from the start can save you headaches and costs down the road. Here are tips for designing products with manufacturing in mind.
Research Production Processes
Early in the design phase, research the common manufacturing methods for your type of product. For example, injection molding for plastics or CNC machining for metals. Understanding the requirements and limitations will inform better design decisions.
Design for Manufacturing Guidelines
Many manufacturers provide design for manufacturing guidelines from their tooling experts. Use these to avoid red flags like walls that are too thin, draft angles that are too low, or tolerances that are too tight. Optimize the design within the process constraints.
Material Selection
Consider the manufacturability of your chosen materials as well as their properties. For example, thermoplastics like ABS are easily injection molded while thermosets can be more challenging. Material choices also impact cycle times, cost, strength, and other factors.
Ease and Efficiency
Simplify designs whenever possible, consolidating parts and fasteners. Allow for easier access, handling, and assembly. Standardize components across your product line when feasible. Simple, efficient designs translate to faster, cheaper production.
Avoid Secondary Processes
Look to minimize secondary production processes like welding, painting, coatings, etc. While sometimes unavoidable, each additional step adds cost and production time. Design to require fewer secondary processes.
Design for Quality
Select materials with sufficient strength, hardness, and durability for long service life.
Analyze how parts and systems could wear over time and use high-wearing materials at friction/mating surfaces.
Prototype with Production Methods
Use production-representative techniques for prototypes whenever possible. 3D print or CNC machine prototypes out of the actual materials and using the actual processes. This reveals manufacturability issues early when easier to address.
Involve Manufacturers Early
Engage with manufacturers while still in the design phase. Get their input on proposed designs. Having manufacturing feasibility on the radar early prevents issues requiring big redesigns later on.
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