DFM assemblies.
Multi-part design.
Assembly cost.
DFM for assemblies. Reduce parts count, simplify assembly, design for repeatable assembly. Tolerance allocation across assembly.
Key principles.
Consolidation
Combine parts where possible. 3D printing enables.
Stack-up
Distribute tolerance across mating parts.
Lead-in chamfers
Chamfered insertions for robot/manual assembly.
Single way
Orient features so part assembles single way only.
Off-shelf
Standard fasteners reduce inventory.
Snap-fits
Eliminate fasteners with snap-fits where possible.
FAQ
Assembly time costs?
Manual labor $30-100/hour. Automation $10-30/hour amortized. Reduce assembly time = save cost.
Tolerance stack-up?
Multiple parts mating. Worst case = sum of tolerances. RSS = √(sum of squares). RSS more realistic.
Self-locating features?
Lead-in chamfers (45° × 1mm typical). Robots can position to ±0.1 mm; chamfer handles error.
Reducing parts count?
Combine parts where possible. 3D printing enables impossible-to-machine consolidation.
Standard fasteners selection?
M3-M10 metric most common. Avoid custom unless needed. Standard saves cost throughout supply chain.
Production volumes effect?
Higher volume justifies investment in automation, custom fasteners, tooling.
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