In the world of modern manufacturing, designing parts is not just about creating something that functions, it needs to ensure it can be made efficiently, affordably, and repeatedly. This is the core of designing for manufacturability. Anyone who has ever worked with a metal fabrication shop knows, there’s a world of difference between a part that looks great in CAD and one that is ready for the shop floor. Good design takes into account the realities of fabrication. Only then can production be maximized and costs reduced.
Designing for manufacturability starts with understanding the limitations and capabilities of the fabrication process. A metal fabrication shop works a wide range of equipment such as; laser cutters, press brakes, welding stations, CNC machines, each with its own limitations and capabilities. The better your design fits within the capabilities of the equipment, the faster and more efficiently you can go from design to completion.
First and foremost, keep it simple. Complexity increases time and cost. While intricate curves and detailed geometries may be appealing, they often require specialized tooling or secondary operations. When working with sheet metal, for example, you can not form a closed loop with common tooling. Similarly, large radii bends (called out radii bends) can require expensive tooling, multiple set ups and or steps to produce.
Standardization is another crucial tool. Try to use uniform materials and tube bend radii throughout your design. Not only does this reduce the number of tool changes a fabricator has to make, but it also allows for batch production and easier quality control.
Tolerances are an area where over engineering can backfire. Specifying tight tolerances across the board might seem like a great idea, but it will dramatically increase production cost. Precision should be reserved for only those dimensions that truly require it. A hole that’s just a mounting point for a screw might not need a ±0.002″ tolerance ±0.01″ could do the job just fine. Over specifying tolerances often results in more expense though longer cycles, increased inspection processes and lower yields. All this leads to higher costs.
Ease of assembly is often overlooked. Whenever possible, design parts to be self-locating or self-fixturing. Tabs, slots, and alignment features can significantly simplify the welding or fastening process. This not only reduces the time required on the floor, but it also increases consistency and part quality. Thinking through how your parts will be handled, rotated, and joined is critical. Any good metal fabrication shop will tell you: parts that “snap together” or naturally align save everyone time and headaches.
Fastening methods matter. Welding is often the method of choice for fastening parts together, but it is not always the most efficient choice, but does have a strong permanent connection. In some cases, using standard fasteners like bolts or rivets can simplify fabrication and improve maintenance. Welding requires robots or skilled labor, post-processing, and often adds to the inspection requirements. If you can achieve the required strength and durability with a fastener, your design may be more practical and cost-effective.
Design reviews with your fabricator are also invaluable. Even if you believe your design is perfect, engaging with a metal fabrication shop early in the process opens the door to insights that only come with hands-on experience. A quick review can help catch issues you might have missed; like maybe your flange interferes with a tooling path, or your specified material isn’t ideal for laser cutting. It’s the kind of collaboration that saves both time and money.
Keep scalability in mind. A design might be easy to fabricate once, but what happens when you need to make a 1,000? Parts that are easy to jig, require few setups, and can be nested efficiently on a sheet of material are ideal for mass production..
At the end of the day, designing for manufacturability is about respecting the hands, and machines, that bring your design to life. It is finding the middle ground between creativity and practicality. Whether you are prototyping or running production, keeping the capabilities and challenges fabrication will face in mind leads to better, faster, and more cost effective production.
Next time you’re about to hit “send” on that design file, take a moment and think like a fabricator. Call your local metal fabrication shop. Ask questions. Collaborate. You might be surprised how a few small design changes can make a big difference.
Because when your design is made with manufacturability in mind, everybody wins—the designer, the fabricator, OEM, and the end user.