The Benefits of Early "Design for Manufacture (DFM)” Discussions with Moulders and Tool Makers
- equipedesign
- May 5
- 6 min read
When embarking on a new product development project, the design process is one of the most critical phases. All the cost, efficiencies, usability for all customers and the overall success of a product, not only its popularity are locked in before its design leaves the cad screen.
While creativity and innovation often take centre stage, practicality and manufacturability are equally vital. Enter the concept of Design for Manufacture (DFM)—a systematic approach that ensures a design is optimized for efficient, cost-effective production.
Whilst this is not a new concept. Its application as an early phase consideration reaps enormous rewards when compared to more traditional development methods of designers and engineers producing a complete design and throwing it over an abstract wall to production. What ensues is an oft lengthy backwards and forwards, usually to the frustration of both parties to find a common ground from which to proceed.
For plastic component design, engaging in early DFM discussions with moulders and tool makers can significantly enhance the success of your product development process. This collaboration not only mitigates risks but also ensures the design is practical and aligned with manufacturing capabilities.
Throughout my career I have found this methodology actually fast tracks development timeframes to tooling release and can often streamline the tool fabrication process as well.
Below, we delve into the key benefits of these early conversations.
1. Minimised Design Revisions
One of the most common pitfalls in product development is the need for design changes after prototyping or tooling has begun. Late-stage revisions can be time-consuming and costly and extend project development timeframes.
Engaging moulders and tool makers early in the design process can help identify potential issues upfront. For example:
A moulder can point out areas where material flow may cause defects like warping or voids.
A tool maker can highlight features that could complicate tooling, such as undercuts or deep drafts.
Addressing these challenges during the design phase reduces the likelihood of costly rework later, saving both time and money.
2. Optimised Tooling Design
Tooling is a significant investment in the manufacturing process, especially for injection-moulded parts. Early DFM discussions allow tool makers to contribute their expertise to optimize the tooling design:
Material selection: Tool makers can recommend materials for the mould that align with your production volume, product material, and budget.
Cooling systems: They can design efficient cooling channels to reduce cycle times and part accuracy and repeatability, improving productivity.
Durability considerations: If the product requires high-volume production, the tool maker might suggest hardened steel moulds, whereas softer aluminium moulds might suffice for low volumes.
Overall tooling cost: Quite often an overly complex part causing an overly complex tool designed as such in an effort to reduce the number of tools can be replaced by two simpler tools with cheaper overall COGS by dividing into two simpler parts moulded from two simpler tools.
By incorporating these insights early, you ensure that the tooling is both cost-effective and durable, meeting your production needs and can be capture in your design earlier in the piece.
3. Improved Material Selection
Material choice plays a critical role in the performance, appearance, and cost of your product. Moulders bring invaluable expertise in this area, as they work daily with a wide range of materials from a range of material suppliers.
New material formulations are being developed and released so regularly it is often difficult to keep abreast of the latest offerings.
Early discussions with moulders can help:
Match material properties with product requirements, such as strength, flexibility, or UV resistance.
Consider secondary processes like painting or welding that might affect material choice.
Evaluate material availability and cost, ensuring supply chain stability. Often a moulder will carry stock of a particular grade in large quantities for other customers. If the particular grade of material meets your products requirements, leveraging on their volume buying power can give your product a competitive edge.
This collaboration ensures the selected material aligns with both design intent, cost competitiveness and manufacturability.
4. Enhanced Manufacturability
DFM discussions encourage designers to think beyond aesthetics and functionality to consider how easily and efficiently the product can be manufactured. Moulders and tool makers can provide insights on:
Part geometry: Suggesting design changes like adding draft angles or reducing wall thickness variations to avoid manufacturing challenges.
Gate placement: Recommending optimal locations for gates to ensure uniform material flow and reduce aesthetic defects like sink marks.
Feature simplification: Identifying features that may be unnecessary or overly complex, streamlining production.
These adjustments not only make manufacturing easier but also lower production costs and reduce lead times.
5. Cost Efficiency
Early collaboration can directly impact the financial bottom line by identifying cost-saving opportunities without compromising quality. For example:
A tool maker might suggest a multi-cavity mould to increase production efficiency for high-volume runs.
A moulder could recommend alternative materials that meet the same requirements at a lower cost. Different material may benefit from different tailored part design like wall thickness.
Both can highlight areas where slight design modifications might reduce tooling complexity, cutting costs.
Additionally, avoiding late-stage revisions, tooling rework, or production delays results in significant dollar and time savings.
6. Reduced Production Risks
Manufacturing involves a host of potential risks, from tool failure to quality issues. Early DFM discussions allow experts to foresee and mitigate these risks:
Moulders can identify potential challenges with material shrinkage, warping, or ejection.
Tool makers can predict tooling wear or failure points and design for longevity.
Both can collaborate on quality control measures, ensuring the product meets specifications consistently.
By addressing these risks proactively, you avoid expensive production delays and ensure smoother operations. Whilst many CAD packages have sophisticated analysis features like draft check etc, often nothing can replace industry experience at the coal face of tooling and production. This is where the art of moulding meets the science of moulding.
7. Faster Time-to-Market
In today’s competitive market, speed is often a critical factor in success. Early DFM discussions help streamline the entire development process:
Identifying and solving potential problems early avoids delays in later stages.
An optimized design means quicker tool fabrication and reduced iteration cycles.
Improved manufacturability translates to faster production ramp-up.
With a robust design and efficient tooling in place, you can get your product to market faster, giving you an edge over competitors.
8. Stronger Supplier Relationships
Building a collaborative relationship with your moulder and tool maker sets the stage for smoother communication throughout the product lifecycle. These early discussions foster mutual trust and understanding, which can:
Lead to better alignment on project goals.
Improve responsiveness during production challenges.
Lay the groundwork for future collaborations on new projects.
Strong supplier relationships ultimately contribute to long-term success and reliability.
Often suppliers are more open to share their knowhow as they feel confident of tenure in the relationship and a future income stream free from the concerns of being sucked for information to teach to their competitors who are less capable but offer a lower quoted price. Generally, you get what you pay for and expertise is valuable and treated as such.
9. Eco-Friendly Design
Sustainability is becoming an essential consideration in modern product development. Moulders and tool makers can help designers create more eco-friendly products by:
Suggesting materials that are recyclable or have lower environmental impact.
Designing moulds for minimal material waste.
Identifying opportunities for part consolidation, reducing assembly complexity and resource consumption.
By incorporating sustainable practices from the start, you create products that align with environmental and consumer expectations.
10. Better End-Product Quality
At the end of the day, product quality is paramount. Early DFM discussions help ensure your design is practical and manufacturable without compromising on quality. From improved material flow to optimized cooling systems, these insights enhance product consistency, durability, and aesthetics.
Early "Design for Manufacture" discussions with moulders and tool makers are an invaluable investment in the success of your product development process. These collaborations lead to designs that are practical, cost-effective, and optimized for manufacturing, all while minimizing risks and accelerating time-to-market. By fostering these early partnerships, you not only streamline your development process but also enhance the overall quality and competitiveness of your product.
The next time you embark on a new design project, remember to involve your moulder and tool maker from the very beginning. Their expertise can make all the difference between a challenging, expensive process and a smooth, successful journey to market.
And the most powerful element, a positive, collaborative relationship, breaking down the walls between the two sides of the same coin.
---
équipe design & consulting , with over 20 years experience in design and manufacture of Medical grade moulded parts and product, including 5 years at the coal face as Operations Manager at a world class medical grade moulding facility; we are specialist in Design for Manufacture (DFM).
Please reach out if you feel you need assistance with your part design for plastic injection moulding, from Design Coaching and Guidance to Full Service Design Consulting.