1. Simplify the Design

   • Reduce Part Count: Minimize the total number of parts in the assembly. This will reduce incoming inspections, shorten assembly time, and decrease overall complexity.
   • Standardize Components: Use off the shelf components whenever possible. They will be more cost-effective and easier to source. Custom parts typically have longer lead times and add complexity to inventory management.
   • Design for Modular Assembly: Modules and subassemblies streamline the assembly process, simplify testing, and facilitate straightforward repair procedures. 

2. Material Selection

   • Choose Common Materials: Materials that are readily available will be easier to source, cutting down on cost and lead times. 
   • Consider Material Properties: Take the manufacturing process into consideration when selecting materials to ensure compatibility. Don’t forget to check that the material properties meet your product specifications. 

3. Assembly Considerations

   • Ease of Assembly: Incorporate alignment features into your parts to decreases assembly complexity and ensure uniformity across your product line. 
   • Minimize Fasteners: Reduce the number of fasteners. When possible, use snap fits, adhesives, or other fastening methods to simplify assembly.
   • Ensure Accessibility: Consider the tools required for assembly. Avoid processes that require specialized tool or techniques. 

4. Manufacturing Processes

   • Select Appropriate Processes: Choose the appropriate manufacturing process for your design. Consider material choice and throughput when selecting the process. 
   • Consider Tolerances: Make sure that the specified tolerance is compatible with the manufacturing method. Avoid excessively tight tolerances. Overly constrained parts can be difficult to achieve and are unnecessary for the product’s function. Plus, they increase inspection time. 
   • Testing & Quality Control: Design parts that are easy to test and inspect during the manufacturing process. Consider testing needs and procedures early in the design process. Identifying defects sooner saves time and money in the long run.

5. Cost Considerations

   • Optimize Production Time: Reduce labor for manufacturing and assembly wherever possible. This may include reducing the number of machining steps or simplifying assembly processes. 
   • Design for Automation: Consider automating your manufacturing processes. Even a simple fixture can help reduce labor costs and increase consistency in your products (Hint: Your quality control team will appreciate this!)
   • Consider Your Pipeline: Plan ahead. A greater CapEx investment may save you time and money in the long run as you scale your manufacturing, especially if you are considering a multi-cavity tool. 

6. Supplier Selection

   • Engage Early: Manufacturing engineers are experts and can provide valuable input. Also, they can identify potential issues before your design is finalized. 
   • Prototype and Test: Creating prototypes and conducting low volume builds are a great way to test drive your design and manufacturing process. This can help uncover manufacturing challenges and provide the opportunity for necessary design adjustments. We recommend prototyping in the same material that’s planned for high volume manufacturing as a way to “design review” your components.

7. Documentation and Communication

   • Clear Documentation: Detailed drawings, specifications, and assembly instructions are key. These documents communicate the design intent to the manufacturing team.
   • Feedback: Strive for continuous improvement by establishing feedback loops between your manufacturing and engineering teams.

At CITO, we design for manufacturability from the start. We take each of these principles into consideration throughout the product life cycle, starting with our first brainstorm session and early prototypes. This helps you to avoid costly redesigns and delays in reaching your next milestone. Contact us today to see how we can support your next project.