NPTEL Syllabus

Design for Manufacture and Assembly(DFMA)

for Industrial Design - Web course
COURSE OUTLINE
The course is designed to introduce the concept and application for design for
manufacturing and assembly in industrial design for practicing designers and
manufacturing engineers as well as design students (graduate and under graduate) who
are going to play a major role in design and development of various industrial products.
Furthermore, the course helps to analyze product design against various process and
equipment combinations to assess cost and manufacturing lead time. The course includes
various examples and few case studies of real product to demonstrate the importance of
manufacturing and assembly implication to design.

NPTEL
http://nptel.iitm.ac.in

Engineering
Design

Contents
Introduction to manufacturing and assembly; Introduction to Design for manufacturing and
assembly concepts; Design for manufacture and assembly methodologies; Selection of
materials and process; Product design for manual assembly, Design for machining, design
for injection molding, design for sheet metal working, design for die casting, design for
powder metal processing, design for Sand casting, Design for investment casting, design
for hot forging, Design for manufacture and CAD.

Module
No

Module Topic

No. of
Hours

Manufacturing- Introduction

Assembly- Introduction

Introduction to design for manufacturing and assembly

Selection of materials and process

Design for machining

Designing for Casting

Design for forming

Design for manufacture &CAD

Total

40

Additional Reading:
Fundamental
manufacturing books,
Technical papers on
manufacturing and
assembly
Coordinators:
Abinash Kumar Swain
Department of DesignIIT
Guwahati

Sl.
No.

Topic

Lecture
Hour

Module I

Introduction to engineering materials, Materials properties

Introduction to manufacturing, Various manufacturing process

Module II

Introduction to mechanical assemblies, Various examples,

Assembly in the context of product development

Introduction to design for manufacturing and assembly, DFMA case

studies, Impact of DFMA to various Industries

Module III

General requirements for early materials and process selection,

Selection of manufacturing process, process capabilities, selection
of materials

Design with materials, design for Brittle fracture, Design for Fatigue
failure, Design for corrosion resistance, Design for wear resistance,
Designing with plastics

Module IV

Product design for manual assembly

Product design for automation

Module V

Introduction to Design for machining, Machining Using Single point

cutting tool, Machining with multi point cutting tool, Machining with
Abrasive wheels, Choice of work material, shape of work material,
machining basic component shapes, Assembly of Components,
Accuracy and Surface finish

Module VI

Design for injection molding, Design for die casting, design for

10

powder metal processing, Design for sand casting, design for

investment casting

Module VII

11

Design for sheet metal working, Design for hot forging

Module VIII

12

Linking CAD and DFMA, Geometric representation in CAD,

Extraction of DFMA data from CAD System

References:
1. J. Lesko, (1999) Industrial Design, Materials and Manufacture Guide, John Willy and
Sons, Inc
2. George E. Dieter and Linda C. Schmidt (2009), Engineering Design, Fourth edition,
McGraw-Hill companies, New York, USA
3. Geoffrey Boothroyd, Peter Dewhurst and Winston Knight (2002) Product Design for
Manufacture and Assembly, Second Edition, CRC press, Taylor & Francis, Florida,
USA
4. O. Molloy, S. Tilley and E.A. Warman (1998) Design for Manufacturing and assembly,
First Edition, Chapman &Hall, London, UK.
5. D. E. Whitney, (2004) Mechanical Assemblies: Their Design, Manufacture, and Role in
Product Development, Oxford University Press, New York
6. A.K. Chitale and R.C. Gupta, (1999) Product design and Manufacturing, Prentice Hall
of India, New Delhi.
7. James G. Bralla (1998) Design for Manufacturability Handbook, Second Edition,
McGraw-Hill companies, New York, USA
8. Geoffrey Boothroyd (2005) AssemblyAutomation and Product Design, Second
Edition, CRC press, Taylor & Francis, Florida, USA
9. G. Q. Huang (1996) Design for X, Concurrent Engineering Imperatives, First Edition,
Chapman &Hall, London, UK
A joint venture by IISc and IITs, funded by MHRD, Govt of India

http://nptel.iitm.ac.in