1. Design with the Manufacturing Process in Mind

Are you planning to stamp, form, machine, or laser cut the part? Each process has specific design considerations. Before finalizing a design, evaluate how the part will be produced and adjust accordingly.

For stamped parts – Avoid deep draws, sharp internal corners, and excessive bends that may necessitate secondary operations.

For machined parts – Minimize unnecessary tight tolerances and complex features that can increase production time.

For formed parts – Account for material springback and flow to prevent distortion.

2. Balance Tolerances for Cost and Performance

Not every feature requires machining to ±0.0005” precision. Tight tolerances can lead to higher scrap rates and extended lead times.

Consider: Can a slightly looser tolerance maintain functionality?

Collaborate with the manufacturing team to establish practical, achievable tolerances that won’t unnecessarily increase costs.

3. Select Materials Suited for Manufacturing

Some materials are easy to machine but difficult to stamp. Others may be lightweight but prone to warping under heat or pressure.

High-strength alloys might require special tooling and slow down stamping processes.

Certain metals are suitable for deep drawing, while others may crack under stress.

Understanding material properties early on can prevent costly issues during production.

4. Engage Tooling and Stamping Experts Early

The simplest way to avoid manufacturability problems is to involve the manufacturing team before finalizing the design.

Tooling engineers can identify potential issues before they escalate into expensive production problems.

Stamping and forming specialists can recommend minor adjustments that preserve functionality while enhancing manufacturability.

DFM analysis tools and simulations can detect potential challenges before production begins.

This proactive approach can save significant time and resources.