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Design for Manufacturing
Why Great Engineering Still Fails in Production
Issue 027
You’ve designed a high-performance electrical component—optimized for function, tested in simulations, and approved by the team. Everything looks great on paper. But when the part reaches production, the bad news hits: it can’t be efficiently stamped, formed, or assembled at scale.
Now, you’re facing expensive rework, last-minute design changes, and frustrating delays.
What went wrong? It wasn’t designed with manufacturability in mind.
This is a common challenge in manufacturing—a disconnect between engineering and production. No matter how perfect a design seems in CAD, if it’s difficult (or impossible) to manufacture efficiently, it fails where it matters most: in production.
The good news? Avoiding these failures is achievable by applying Design for Manufacturing (DFM) principles early in the process.
Let’s talk about why great designs fail in production—and how you can prevent it from happening.
1/3 | Why Some of the Best Engineering Designs Fail in Production
Engineering and manufacturing don’t always speak the same language—but they should. A design might be functionally sound, but if it creates manufacturing bottlenecks, excessive material waste, or tooling challenges, it’s not actually a good design.
Here’s what often goes wrong:
🔴 Overly Tight Tolerances – Strict tolerances can increase machining and stamping costs and may lead to unnecessary rework. In many cases, relaxed tolerances can achieve the same performance at a lower cost.
🔴 Complex Geometries That Are Difficult to Manufacture – Intricate shapes with sharp corners or deep draws might look impressive in CAD, but they can be challenging to produce efficiently at scale.
🔴 Inappropriate Material Choices – Some materials may crack or warp during stamping or forming. If material behavior isn’t considered, production failures are likely.
🔴 Ignoring Tooling and Die Constraints – Designs requiring multiple setups, excessive trimming, or specialized tooling can increase costs and production time. Aligning designs with existing tooling capabilities can save both time and money.
Sound familiar? These issues don’t just lead to delays—they impact efficiency, cost, and overall product quality.
2/3 | How to Optimize Designs for Manufacturability (Without Compromising Function)
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.
3/3 | Final Thoughts: Design for Manufacturing Is Essential for Success
A great engineering design isn’t just about functionality—it’s about how efficiently it can be produced.
By incorporating Design for Manufacturing principles early, you can:
Minimize last-minute design changes
Prevent production delays and tooling issues
Reduce costs while maintaining product quality
The optimal time to address manufacturability concerns? Before production even starts.
Gromax Precision Die & Mfg., Inc. specializes in designing and manufacturing precision metal stamped parts and tooling, including progressive stamping dies and custom equipment. With an on-time delivery rate of 99.68% and a defect rate of just 0.066%, the company ensures exceptional reliability and quality.
Gromax is ISO 9001:2015 certified and ITAR registered, serving industries such as medical, defense, aerospace, industrial automation, and automotive with high-quality, innovative solutions.