6 Key Principles in the Design for Manufacturing of Small Plastic Parts

The philosophy behind designing for manufacturing (DFM) is the focus on ease of manufacture. It’s a principle used in a wide range of industries, from the selection of materials to the complexity and design of the product. This mentality can often result in an increase in both productivity and profit, and can be applied to a wide range of components, from cable management solutions to flange protection solutions.

Here are 6 principles to help you adopt a DFM approach:

Use the smallest number of components possible

The more joins, hinges or connections that a component possesses, the more opportunities exist for defects and component failure. The more simplistic a component is, the less chance it has of going wrong. Assembly will be more efficient and have fewer issues with inventory management. If in doubt, keep it simple.

Don’t reinvent the wheel

Where possible, it’s always a good idea to try to recycle components that you’ve produced in another project, rather than producing a similar component from scratch with the risks and potential for delays and defects that this entails. The DFM approach means engineering products to use as many common parts as possible.

Always consider the manufacturing process

When designing a component, try to make it as simple as possible for manufacturing. This includes shape, material and finish. Function over aesthetics should take precedence for maximum efficiency.

Limit the scope for error

By minimising the number of machine operations required to make the component, you’re not only reducing the amount of time it’ll take to produce, you’re reducing the possibility of machine malfunction delays and opportunity for defects and flaws.

Be realistic with tolerance expectations

Instead of pushing design boundaries that may affect the structural tolerances of a part, use smart design to achieve your product goals and protect any potential component weaknesses.

Make it as simple to assemble as possible

For maximum efficiency, design components that are simple to assemble. Removing any doubt about how a component fits together reduces the risk of damage and therefore the need to replace components.

If you follow these key principles, you can achieve a DFM mentality and reap the efficiency and profitability benefits that this entails.