Function first.
Cost optimized.
DFM mindset.
Smart design considers manufacturing cost from the start. Internal corner radii, tolerance allocation, material choice, feature placement all impact cost. Get DFM right and cut 30-50% from typical parts.
Key principles.
Single biggest
Generous internal radii enable larger tools and faster cutting. Often 2-3× cost difference vs sharp corners.
Per feature
Tight tolerances only where function requires. Default ±0.1 mm. Save tighter for critical fits.
Process-friendly
6061 aluminum cheap and machinable. 7075 only when strength needed. Steel only when aluminum inadequate.
Avoid custom
Standard hole sizes, threads, bearing fits. Custom dimensions add tooling and time.
Minimize setups
Design for single-setup machining. Each new setup adds time and tolerance stack.
From bar/plate
Design to standard bar diameters, plate thicknesses. Saves material vs custom stock.
FAQ
How much can DFM save?
Typically 20-50% on machining cost. Sometimes more for poorly-DFM designs.
Functional vs cosmetic features?
Functional features must meet spec. Cosmetic features can use cheaper alternatives (powder coat vs anodize).
When to invest in DFM?
Always. Quote includes free DFM review. Implement suggestions or ignore — customer choice.
Volume affects DFM choices?
Yes. Low volume: minimize tool changes, fixturing. High volume: invest in custom tooling for cycle time reduction.
Tolerance vs cost relationship?
Each tighter tolerance class adds 30-100% feature cost. ±0.025 vs ±0.1 typically 2× cost.
Material vs machining cost?
Material 30-50% of part cost typically. Cheaper material grade saves directly. Premium material adds proportionally.
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