Optimize CAD Models with Design for Manufacturing (DFM)

The fast-paced manufacturing knows how important it is to understand the guidelines of design for manufacturing (DFM). Designers and engineers opt for DFM-embedded CAD software with companies aiming to manufacture efficient products. 

From reducing manufacturing costs to streamlining the 3D CAD modeling service, DFM can help you with all. This blog will inform you about all the essential aspects and how it can help you. 

Understanding Manufacturing Processes

Explore the process before optimizing CAD model design for manufacturing (DFM).

– Manufacturing Processes

Here are some essential factors:

• Machining: This process involves the precise cutting of materials. According to industry standards, tolerances of ±0.005 inches are optimal. The tighter the tolerance, the higher the cost.
• Casting: It is the method of pouring liquid metal into molds. Often experts consider casting for manufacturing complex shapes. However, careful design and consideration of dimensions are required.
• Forging: When metals are put under compressive forces to shape them, it’s called forging. This process is effective in crafting substantial parts. However, it requires careful precision and control of temperature and materials.
• Injection Moulding: This process can produce high volumes of 3D models. Its tolerances are usually around ±0.002 inches.

– Tolerances and Fits

In manufacturing processes, tolerances are essential components. It dictates acceptable variations in dimensions. You must remember the tolerances impact of 3D CAD models‘ assembly and functions. Tight tolerances may lead to higher machining. This can cost you more than usual.

– Surface Finishes and Heat Treatment

Surface finishes can affect the product’s aesthetics and control its wear resistance. In addition, the heat treatment on products enhances their material properties. Engineers consider these two factors before designing products for manufacturing. This ensures the product’s performance and longevity.

Design for Manufacturing Guidelines

Understanding the design guidelines for manufacturability, also known as DFM, is crucial for every manufacturing engineer or designer. A complete knowledge of DFM helps you to optimize your CAD models. It enables you to reduce costs, improve product quality, and enhance the efficiency of product manufacturing.

Here’s an overview:

– Simplifying Geometry and Reducing Part Count

When you simplify complex CAD models and reduce their parts, the process saves 80% of the manufacturing costs. To achieve this, you can use the following strategies: 

• Combine functions to design parts for products. This minimizes the component count and also reduces manufacturing costs.
• Instead of complex shapes, opt for simple geometric shapes. Such 3D modeling designs are easy to manufacture.

You must take note that fewer components indicate faster production cycles. That means a smaller number of elements means minimal setup time and machining.

– Designing for Assembly and Disassembly

The manufacturing process gets streamlined when you design products for easy assembly. You can do this with the following strategies:

• Use interlocking features while creating CAD models. This strategy eliminates the need to install additional fasteners. Also, such features can easily align during assembly and improve product performance.
• Create modular designs where parts can be easily modified, replaced, or added. This promotes better maintenance.

Designing assembly processes can reduce labor costs by almost 30%. Furthermore, it reduces the chances of human errors and enhances the overall product quality.

– Avoiding Undercuts and Draft Angles

Undercuts often complicate molding designs. It requires additional cores and slides, increasing manufacturing costs in the process. Thus, expert designers advise avoiding it.

You can avoid it by the following techniques:

• Use optimal draft angles while creating 3D models. Designers often recommend a draft angle of at least 1° to 3°. This makes it easier to remove parts from the models. Also, remember that higher drafting angles can call for significant defects.
• Design 3D models without undercuts, wherever possible. You can also include tapered features in your CAD models. Such features enable faster ejection while still maintaining structural integrity.

Using CAD Tools for DFM Analysis

The CAD tools of design for manufacturing (DFM) analysis assist engineers and designers in creating optimized products and increasing work efficiency. Here are some tools:

– Design for Assembly (DFA) Analysis

This tool simplifies the assembly process by reducing the number of parts. With the help of this tool, you can streamline the designs and reduce assembly time This further lowers labor costs and reduces human errors.

The DFA tool also allows users to visualize the assembly sequence. It also helps identify potential challenges in the early design phase.

– Design for Manufacturing (DFM) Analysis

It allows designers to optimize their designs and produce better products. The tool considers factors like material selection and production methods. Furthermore, engineers and architects use DFM to reduce manufacturing costs and minimize reworking on the same design.

Often industry professionals use DFM-embedded CAD tools. That’s because it shares real-time feedback and allows designers to make changes before manufacturing products.

– Tolerance Stack-Up Analysis

Engineers use this tool to check the total tolerance in assemblies. The Tolerance Stack-Up Analysis tool also ensures all parts fit together and that there are no excessive gaps. In addition, proper tolerance management can reduce production errors. 

Did you know that advanced CAD software can simulate the effect of tolerance on products? Such CAD programs help designers adjust dimensions and check component compatibility.

Conclusion

A complete understanding of designs for manufacturing (DFM) is necessary while creating product designs. The tools and guidelines associated with 3D modeling help users make efficient products. Moreover, essential analyzing tools are crucial for drafting CAD models that are cost-effective and easy to manufacture.

Are you ready to take your product designs to the next level? Get in touch with Shalin Design — a world-class design and drafting provider. Known for catering to diverse industries and producing effective results, Shalin Design and its team can be your next big ticket to success.