Design for Manufacturability: 7 Tips to Improve Part Quality, Lead Times, and Cost

When moving a concept from CAD to production, the best designs aren’t just functional, they’re designed with manufacturing in mind. That’s where Design for Manufacturability (DFM) comes in. By incorporating manufacturing considerations early in the design stage, you can reduce lead times, minimize costs, and improve overall part quality.

Here are seven practical DFM tips that can help make your next project more efficient and production-ready.

1. Choose Materials Early and Match Them to the Process

Material selection impacts everything from tooling requirements to finishing options. For example:

Aluminum is lightweight and machines quickly, making it cost-effective for many aerospace and electronics components.
Stainless steel offers corrosion resistance but may require slower machining speeds.
Exotics like titanium demand specialized tooling and expertise, which can affect lead time.

By locking in material choices early, you can account for machinability, availability, and cost before the design is finalized.

2. Keep Tolerances Realistic

While tight tolerances are sometimes critical, over-specifying them can drive up cost and complexity. Work with your manufacturing partner to:

Identify where precision is functionally necessary.
Loosen tolerances in non-critical areas.
Standardize dimensions to reduce setup and inspection time.

3. Minimize Complex Geometries (Where Possible)

Complex internal features, deep pockets, or sharp internal corners can slow production or require specialty tooling. Consider:

Adding radii to internal corners.
Reducing unnecessary undercuts.
Using standard drill sizes instead of custom diameters.

4. Standardize Features and Hardware

Whenever possible, use standard hole sizes, threads, and fasteners. This:

Reduces custom tooling needs.
Shortens procurement time for components.
Simplifies assembly and maintenance.

5. Plan for Fixturing and Tool Access

Parts that are difficult to fixture or machine from certain angles may require additional setups, increasing lead time. During design:

Avoid features that block tool access.
Design parts so they can be machined in fewer setups.
Think about how the part will be held during machining and finishing.

6. Consider the Entire Manufacturing Workflow

DFM doesn’t end with machining. Think about:

Secondary processes like anodizing, painting, or assembly.
Dimensional changes from heat treatment or plating.
How your part will be inspected and tested.

7. Communicate Early and Often

The most overlooked DFM tip? Involve your manufacturing partner as soon as possible. Sharing CAD models, preliminary drawings, and functional requirements early allows for:

Faster identification of potential challenges.
Collaborative solutions that save time and money.
A smoother transition from prototype to production.

Bottom line:
Designing with manufacturability in mind isn’t about compromising your vision — it’s about ensuring that your vision can be built efficiently, cost-effectively, and with consistent quality.