Many engineers are well-versed in design for manufacturability (DFM) when it comes to injection molded plastics – a process that demands uniquely optimized designs, even for basic products. But DFM is obviously not limited to only plastic materials. Whether you’re working with molded rubber products or machined metal components, DFM collaboration between you and your manufacturer can truly make or break your project’s success.
At Panova, we view DFM as more than a basic design review. It’s a modus operandi that’s fully integrated into our process, extending from the first conversation all the way through to production launch. Here’s what that looks like in action, and why it matters for the success of your products.
Design your products with manufacturing in mind:
DFM Defined: A Proactive Approach to Optimizing Your Product Design
Essentially, DFM is the process of optimizing a part’s design in accordance with the chosen materials and the production process to follow. Our goal is to make your manufacturing process easier, faster, more reliable and more cost-effective – never compromising on end product quality or performance. Naturally, that means taking into account how the part will be molded, machined, stamped, and/or assembled, identifying potential challenges thereof before they become actual problems.
In that sense DFM is proactive, not reactive. It’s a process best engaged with early, when your product design is still flexible and the production process is not yet established. Ideally, you want detailed input from manufacturing experts who’ve seen what works and what doesn’t in developing a myriad of different real-world products. Enter Panova, backed by nearly half a century of successful customer collaboration.
DFM in Plastic Injection Molding
DFM principles like uniform wall thickness, draft angles, and minimizing undercuts are well-known in the realm of plastic manufacturing. Injection molding, in particular, can have a steep cost curve for tooling. In other words, mistakes are expensive and rework is painful. That’s why many engineers are trained to think about manufacturability early when designing plastic parts.
Additionally, gate size and location play a critical role in ensuring proper material flow and minimizing defects. Mold flow analysis is often used during the design phase to predict how the plastic will fill the mold, helping to identify potential issues such as sink marks and flow lines before tooling begins.
DFM in Rubber Molding and Manufacturing
Rubber manufacturing presents its own set of challenges. Material flow and shrinkage are less consistent than with plastic, and factors like cure time and flash control must be considered upfront. The right parting line, gate location, gate size, and tool design can dramatically affect quality and yield. Mold flow analysis, while more commonly associated with plastics, can also be useful in rubber applications to anticipate potential defects and optimize flow.
Panova can help you think through these details early, guiding material selection, mold design, and even how a part will be de-flashed or tested. The earlier we’re involved, the more value we can bring to the table.
DFM for Precision Metal Products
Metal components – whether stamped, die-cast, or machined – likewise benefit from DFM. Issues like tolerance stack-up, edge condition, or secondary ops (like deburring or plating) can introduce unexpected costs or delays. And over-engineering a part can lead to wasted material, worn tooling, or unnecessarily tight specs.
By reviewing these factors upfront, we help engineers find smarter, simpler ways to achieve the same performance at a lower cost and with better manufacturability.
How Panova Brings DFM to Life Through Your Project
At Panova, DFM is seamlessly built into the way we work. Every project starts with a structured RFQ kickoff meeting. We bring the right team into the room early – including engineering, supply chain, and quality control experts – to evaluate the design from all angles.
Our DFM Process:
- Structured RFQ kickoff meetings
- Cross-functional collaboration from day one
- A detailed engineering checklist for every project
- Order kickoff meetings to ensure smooth launches
It’s all part of our commitment to “Simply Solve” – bringing together experience, process, and teamwork to make our clients’ lives easier.
When we help engineers design better parts, and help companies launch with fewer headaches, we’re doing more than just manufacturing. We’re being the kind of partner that we’d want to work with.
Designing Your Products for Manufacturability and Optimizing Your Project for Success
Discover how early DFM collaboration can reduce costs, improve quality, and accelerate time to market. Ready to streamline your next project? Let’s talk about how DFM can help you design smarter and launch faster.