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How do you design for manufacturability when working with different materials?

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Designing for manufacturability (DFM) is a crucial step in any CNC manufacturing project. It means optimizing your design to reduce costs, improve quality, and speed up production. But how do you apply DFM principles when working with different materials? In this article, we'll cover some of the main factors to consider when choosing and designing for various CNC machining materials.

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1 Material properties

Different materials have different physical and mechanical properties, such as density, hardness, strength, ductility, and thermal expansion. These properties affect how the material behaves during machining, as well as the final performance of the part. For example, harder materials require more cutting force and wear out the tools faster, while softer materials may deform or chip easily. Therefore, you need to select a material that suits your part's function, geometry, and tolerance requirements, and adjust your design accordingly.

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2 Material availability

Another factor to consider when designing for manufacturability is the availability and cost of the material. Some materials are more common and cheaper than others, which can affect your budget and lead time. For example, aluminum is widely used in CNC machining because it is lightweight, strong, and easy to machine, while titanium is more expensive and rare, but offers superior strength and corrosion resistance. You also need to check the standard sizes and shapes of the material stock, and try to minimize the amount of waste and excess material.

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3 Material compatibility

When designing a part that involves multiple materials, you need to consider how they interact with each other. For example, if you are using different metals, you need to account for the potential galvanic corrosion that can occur when they are in contact with an electrolyte. You also need to consider the thermal expansion coefficients of the materials, and how they affect the fit and clearance of the parts. Additionally, you need to choose the appropriate fasteners, adhesives, or welding methods to join the parts securely.

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Claire-Marie N.

Scientist, Autisic, IBD Warrior
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It aslo helps to consider the practical aspects of process the materials on house. If you select something, that seems to match all properties and requirements, then fail to consider process applicability within the scope of current resources, it either fails, or requires unaccounted for financial investment and more time to develop a process. Causing delays and financial loss, and sometimes, stopping production. People omit operation processes too often, or consider it far too late in material selection, testing and qualification.

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4 Material finish

The final factor to consider when designing for manufacturability is the finish of the material. The finish refers to the surface quality, texture, and appearance of the part, which can affect its function, aesthetics, and durability. Depending on the material and the part's purpose, you may need to apply different finishing techniques, such as polishing, sanding, coating, or painting. You need to specify the desired finish level and type in your design, and factor in the additional time and cost of the finishing process.

Designing for manufacturability when working with different materials can be challenging, but rewarding. By following these tips, you can optimize your design for CNC machining and achieve better results.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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William Maxwell

OSR turbine field service engineer
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Ask for the machinists input, the guys on the tools are the ones cutting the metal, often they'll point out something that doesn't seem obvious when sat at a computer.

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Steven Wylie

Design Engineer
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Think of how it's going to be machined / manufactured and if it needs to have all the small rads, internal square corners etc.

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Mike Rininger

Operations Specialist at Woodward, Inc.
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Other things to consider are set-ups. How many times does the part have to be handled before completion? Try to do as much machining as you can in one set-up. This does not mean you have to get a multi-axis machine. But you do have to be creative. The fewer setups you have to do, the quicker you can turn them around.

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Robert Morton

Design Engineer at Pipelines 2 Data
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When you are doing the design work of a part for manufacture, consider what the source of the part is: 1. Metric and imperial standard components (plates, sheet, etc.) can vary depending on where you are getting the part machined. If at all, consider the use of either/or (12mm thick part can be made with either 12mm or 1/2" thick plate, 12.2mm thick part can only be used with 1/2" thick plate unless sustantial machining is done) 2. Just because a standard thickness of plate/sheet is used doesn't mean that will be the actual thickness of the component. Tolerancing and surface cleanup will reduce the thickness. 3. Ensure source components (especially tube/pipe) can be sourced from various suppliers.

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How do you design for manufacturability when working with different materials?

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1 Material properties

2 Material availability

3 Material compatibility

4 Material finish

5 Here’s what else to consider

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