Professional Documents
Culture Documents
Learning objectives
Design for manufacturing (DFM)
—Casting and molding
—Machining
—General rules
Concept and
Definition
Product and Implement and Production Launch and
Feasibility Process Design Validate and Stock Closure
Alpha Beta
BUILDS
Concept and
Definition
Product and Implement and Production Launch and
Feasibility Process Design Validate and Stock Closure
Alpha Beta
BUILDS
Source: Design for Cast and Molded Parts: Bertcher, Brod, Lee, Wehr
http://slideplayer.com/slide/3368211/
Design for Manufacturing and Assembly 11
U.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
www.build4scale.org
Casting And Molding
Process design guidelines
Source: Design for Cast and Molded Parts: Bertcher, Brod, Lee, Wehr
http://slideplayer.com/slide/3368211/
Design for Manufacturing and Assembly 12
U.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
www.build4scale.org
Casting And Molding
Process design guidelines (cont.)
Material will shrink as it cools (account for this change during the
design phase)
Use inserts for a family of parts (i.e., parts with similar shapes)
—An insert can be used to change specific features of a part; the
whole tool does not need to be altered
Use a simple parting line
—Where two mold sides come together is the parting line
—Simple parting lines reduce tool cost/time and increase quality
Note: Casting does not allow for tight tolerances/detail so you cast
extra material and then machine out the detail. The trade-off is
that casting is usually a separate company with margin needs then
marked up by machining company along with time in transit and
coordination.
Video: Automated
printed
circuit assembly
Source: www.EngineeringToolBox.com
Design for Manufacturing and Assembly 37
U.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
www.build4scale.org
Design For Assembly
Examples - calculating DFM Index
Source: www.EngineeringToolBox.com
Design for Manufacturing and Assembly 38
U.S. DEPARTMENT OF ENERGY • OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY
www.build4scale.org
Design For Assembly
Example – Altered design
Cost implications
—Consolidation may require the use of different materials and
manufacturing processes (i.e., steel stamping versus die
casting)
Design and manufacturing process complexity
Company description
—Daylight emulator: fake skylight with color tunable LED light
that can simulate daylight (sunrise to sunset) with user-facing
mobile app or linked to outdoor daylight sensors
Company type
√
—Product
—Material
—Manufacturing process
—Manufacturing service
—Manufacturing operations
Year 4 - Retreat
Pre- Beta
Alpha prototypes Pilot prototypes
alpha prototypes