Design For Manufacturing and Assembly

Ken Youssefi UC Berkeley
1
Design for Manufacturing and Assembly
Design for manufacturing (DFM) is design based on
minimizing the cost of production and/or time to market
for a product, while maintaining an appropriate level of
quality. The strategy in DFM involves minimizing the
number of parts in a product and selecting the appropriate
manufacturing process.

Design For Assembly (DFA) involves making attachment
directions and methods simpler.
2
DFM and DFA Benefits
It reduces part count thereby reducing cost. If a
design is easier to produce and assemble, it can
be done in less time, so it is less expensive.
Design for manufacturing and assembly should
be used for that reason if no other.

It increases reliability, because if the production
process is simplified, then there is less
opportunity for errors.
It generally increases the quality of the product for the
same reason as why it increases the reliability.
3
DFM and DFA
DFM and DFA starts with the formation of the
design team which tends to be multi-disciplinary,
including engineers, manufacturing managers,
cost accountants, and marketing and sales
professionals.

The most basic approach to design for
manufacturing and assembly is to apply design
guidelines.

You should use design guidelines with an
understanding of design goals. Make sure that the
application of a guideline improves the design
concept on those goal.
4
DFM and DFA Design Guidelines
Minimize part count by incorporating multiple functions into
single parts. Several parts could be fabricated by using different
manufacturing processes (sheet metal forming, injection
molding). Ask yourself if a part function can be performed by a
neighboring part.
5
Modularize multiple parts into single sub-assemblies.
6
Design to allow assembly in open spaces, not
confined spaces. Do not bury important
components.
7
Parts should easily indicate orientation for insertion.
Parts should have self-locking features so that the
precise alignment during assembly is not required. Or,
provide marks (indentation) to make orientation
easier.
8
Standardize parts to reduce variety.
9
Design parts so they do not tangle or stick to each
other.
10
Distinguish different parts that are shaped
similarly by non-geometric means, such as color
coding.
11
Design parts to prevent nesting. Nesting is when
parts are stacked on top of one another clamp to
one another, for example, cups and coffee lids
12
Design parts with orienting features to make
alignment easier.
13
Provide alignment features on the assembly
so parts are easily oriented.
14
Design the mating parts for easy insertion. Provide
allowance on each part to compensate for
variation in part dimensions.
15
Design the first part large and wide to be stable and
then assemble the smaller parts on top of it
sequentially.
Insertion from the top
is preferred.
16
If you cannot assemble parts from the top down
exclusively, then minimize the number of
insertion direction. Never require the assembly to
be turned over.
17
Joining parts can be done with fasteners (screws,
nuts and bolts, rivets), snap fits, welds or
adhesives.
18
19
Minimizing the Number of Parts
To determine whether it is possible to combine neighboring
parts, ask yourself the following questions:
If the answer to all questions is NO, you should
find a way to combine the parts.
Must the parts move relative to each other?
Must the parts be electrically or thermally
insulated?
Must the parts be made of different material?
Does combing the parts interfere with
assembly of other parts?
Will servicing be adversely affected?
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Minimizing the Number of Parts
The concept of the theoretical minimum number of parts
was originally proposed by Boothroyd (1982).
During the assembly of the product, generally a part
is required only when;
1. A kinematic motion of the part is required.
2. A different material is required.
3. Assembly of other parts would otherwise be
prevented.
If non of these statements are true, then the part is not
needed to be a separate entity.

KI SS Keep I t Simple Stupid
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DFM Design Guidelines
Another aspect of design for manufacturing is to make
each part easy to produce.
The up to date DFM guidelines for different processes
should be obtained from production engineer
knowledgeable about the process. The manufacturing
processes are constantly refined.
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I njection Molding
Injection Molding
Fabrication of Plastics
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I njection Molding
Minimize section thickness,
cooling time is proportional to
the square of the thickness,
reduce cost by reducing the
cooling time.
Provide adequate draft
angle for easier mold
removal.
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I njection Molding
Avoid sharp corners, they
produce high stress and
obstruct material flow.
Keep rib thickness less than
60% of the part thickness in
order to prevent voids and
sinks.
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I njection Molding
Provide smooth transition,
avoid changes in thickness
when possible.
Keep section thickness uniform
around bosses.
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I njection Molding
Use standard general tolerances, do not tolerance;
Dimension Tolerance Dimension Tolerance
0 d 25 0.5 mm 0 d 1.0 0.02 inch
25 d 125 0.8 mm 1 d 5.0 0.03 inch
125 d 300 1.0 mm 5 d 12.0 0.04 inch
300 1.5 mm 12.0 0.05 inch
Standard thickness
variation.
Minimum thickness recommended;
.025 inch or .65 mm, up to .125 for large
parts.
Round interior and exterior corners to
.01-.015 in radius (min.), prevents an
edge from chipping.
27
Rotational Molding
A predetermined amount of plastic, powder or liquid form,
is deposited in one half of a mold.
The mold is closed.
The mold is rotated biaxially inside an oven.
The plastics melts and forms a coating over the inside
surface of the mold.
The mold is removed from the oven and cooled.
The part is removed from the mold.
Rotational molding process consists of six steps
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Rotational Molding Machines
Rock and roll machine
Vertical wheel machine
Shuttle machine
Turret machine
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Rotational Molding
Advantages
Molds are relatively inexpensive.
Rotational molding machines are much less
expensive than other type of plastic processing
equipment.
Different parts can be molded at the same time.
Very large hollow parts can be made.
Parts are stress free.
Very little scrap is produced
30
Rotational Molding
Limitations
Can not make parts with tight tolerance.
Large flat surfaces are difficult to achieve.
Molding cycles are long (10-20 min.)
Materials
Polyethylene (most common), Polycarbonate (high heat
resistance and good impact strength), Nylon (good wear
and abrasion resistance, good chemical resistance, good
toughness and stiffness).
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Rotational Molding
Polycarbonate wall thickness is typically between
.06 to .375 inches, .125 inch being an ideal
thickness.

Polyethylene wall thickness is in the range of .125
to .25 inch, up to 1 inch thick wall is possible.

Nylon wall thickness is in the range of .06 to .75
inch.
Nominal wall thickness
32
Rotational Molding Examples
33
Rotational Molding Examples
34
Sheet-metal Forming
35
Sheet-metal Forming
36
Sheet-metal Forming
37
DFM Design Guidelines - Casting
Casting, one of the oldest manufacturing processes, dates
back to 4000 B.C. when copper arrowheads were made.
Casting processes basically involve the introduction of a
molten metal into a mold cavity, where upon
solidification, the metal takes on the shape of the mold
cavity.
Simple and complicated shapes can be made from
any metal that can be melted.
Example of cast parts: frames, structural parts,
machine components, engine blocks, valves, pipes,
statues, ornamental artifacts..
Casting sizes range form few mm (teeth of a zipper)
to 10 m (propellers of ocean liners).
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Casting Processes
1. Preparing a mold cavity of the desired shape with
proper allowance for shrinkage.
2. Melting the metal with acceptable quality and temp.
3. Pouring the metal into the cavity and providing
means for the escape of air or gases.
4. Solidification process, must be properly designed
and controlled to avoid defects.
5. Mold removal.
6. Finishing, cleaning and inspection operations.
39
Sand Casting Terminology
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Casting Defects
Hot spots thick sections cool slower than other sections
causing abnormal shrinkage. Defects such as voids, cracks
and porosity are created.
41
Casting Defects and Design Consideration
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Recommended minimum section thickness
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DFM Design Guidelines Machining

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Ken Youssefi UC Berkeley

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