2. Ken YoussefiUC 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.

3. Ken YoussefiUC Berkeley 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.

4. Ken YoussefiUC Berkeley 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.

5. Ken YoussefiUC Berkeley 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.

6. Ken YoussefiUC Berkeley 5 DFM and DFA Design Guidelines Modularize multiple parts into single sub-assemblies.

7. Ken YoussefiUC Berkeley 6 DFM and DFA Design Guidelines Design to allow assembly in open spaces, not confined spaces. Do not bury important components.

8. Ken YoussefiUC Berkeley 7 DFM and DFA Design Guidelines 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.

9. Ken YoussefiUC Berkeley 8 DFM and DFA Design Guidelines Standardize parts to reduce variety.

10. Ken YoussefiUC Berkeley 9 DFM and DFA Design Guidelines Design parts so they do not tangle or stick to each other.

11. Ken YoussefiUC Berkeley 10 DFM and DFA Design Guidelines Distinguish different parts that are shaped similarly by non-geometric means, such as color coding.

12. Ken YoussefiUC Berkeley 11 DFM and DFA Design Guidelines 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

13. Ken YoussefiUC Berkeley 12 DFM and DFA Design Guidelines Design parts with orienting features to make alignment easier.

14. Ken YoussefiUC Berkeley 13 DFM and DFA Design Guidelines Provide alignment features on the assembly so parts are easily oriented.

15. Ken YoussefiUC Berkeley 14 DFM and DFA Design Guidelines Design the mating parts for easy insertion. Provide allowance on each part to compensate for variation in part dimensions.

16. Ken YoussefiUC Berkeley 15 DFM and DFA Design Guidelines 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.

17. Ken YoussefiUC Berkeley 16 DFM and DFA Design Guidelines 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.

18. Ken YoussefiUC Berkeley 17 DFM and DFA Design Guidelines Joining parts can be done with fasteners (screws, nuts and bolts, rivets), snap fits, welds or adhesives.

19. Ken YoussefiUC Berkeley 18 DFM and DFA Design Guidelines

20. Ken YoussefiUC Berkeley 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?

21. Ken YoussefiUC Berkeley 20 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. KISS – Keep It Simple Stupid

22. Ken YoussefiUC Berkeley 21 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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43. Ken YoussefiUC Berkeley 42 DFM Design Guidelines Injection Molding Injection Molding Fabrication of Plastics

44. Ken YoussefiUC Berkeley 43 DFM Design Guidelines Injection 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.

45. Ken YoussefiUC Berkeley 44 DFM Design Guidelines Injection 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.

46. Ken YoussefiUC Berkeley 45 DFM Design Guidelines Injection Molding Provide smooth transition, avoid changes in thickness when possible. Keep section thickness uniform around bosses.

47. Ken YoussefiUC Berkeley 46 DFM Design Guidelines Injection Molding Use standard general tolerances, do not 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.

48. Ken YoussefiUC Berkeley 47 DFM Design Guidelines 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

49. Ken YoussefiUC Berkeley 48 Rotational Molding Machines Rock and roll machine Vertical wheel machine Shuttle machine Turret machine

50. Ken YoussefiUC Berkeley 49 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

51. Ken YoussefiUC Berkeley 50 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).

52. Ken YoussefiUC Berkeley 51 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

53. Ken YoussefiUC Berkeley 52 Rotational Molding Examples

54. Ken YoussefiUC Berkeley 53 Rotational Molding Examples

55. Ken YoussefiUC Berkeley 54 DFM Design Guidelines Sheet-metal Forming

56. Ken YoussefiUC Berkeley 55 DFM Design Guidelines Sheet-metal Forming

57. Ken YoussefiUC Berkeley 56 DFM Design Guidelines Sheet-metal Forming

58. Ken YoussefiUC Berkeley 57 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).

59. Ken YoussefiUC Berkeley 58 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.

60. Ken YoussefiUC Berkeley 59 Sand Casting Terminology

61. Ken YoussefiUC Berkeley 60 Casting Defects Hot spots – thick sections cool slower than other sections causing abnormal shrinkage. Defects such as voids, cracks and porosity are created.

62. Ken YoussefiUC Berkeley 61 Casting Defects and Design Consideration

63. Ken YoussefiUC Berkeley 62 DFM Design Guidelines - Casting Recommended minimum section thickness

64. Ken YoussefiUC Berkeley 63 DFM Design Guidelines - Casting

65. Ken YoussefiUC Berkeley 64 DFM Design Guidelines – Machining