What are the most efficient ways to design parts for assembly and post-processing?

Totally on board with you! Using CAD software is like a game changer!!! it's not just effective, it's downright crucial when you're crafting models for assemblies. I always say, better to mess up in the software than in real life because fixing things with a few clicks beats dealing with expensive real-world blunders. And when it comes to putting parts together, CAD makes it a breeze to plan and optimize. You can even run cool simulations to check for potential hiccups. Honestly, CAD software brings a ton of perks to the table, and I can't imagine doing it any other way.

A good and comfortable (for you) CAD software is very important! As a beginner you might like to try Fusion 360 as it is free for hobbyists and has many industrial level capabilities, as well as cloud computing. As professionals we usually stick to the standard SolidWorks or Autodesk’s many platforms. These softwares are great tools for accurate modelling and assemblies and they come with extra tools for simulation and analysis.

Totally on board with you! Using CAD software is like a game changer!!! it's not just effective, it's downright crucial when you're crafting models for assemblies. I always say, better to mess up in the software than in real life because fixing things with a few clicks beats dealing with expensive real-world blunders. And when it comes to putting parts together, CAD makes it a breeze to plan and optimize. You can even run cool simulations to check for potential hiccups. Honestly, CAD software brings a ton of perks to the table, and I can't imagine doing it any other way.

Widely used method and most efficient one is using CAD software. I am working as a 3D modeler from last 8 years. I am steel detailer. I use SDS2 for 3D modeling, 2D fabrication drawings, CNC and other requires files output for steel fabrication of the structural steel building. We provide detail shop drawings for every single piece required in custruction of steel buildings. So SDS2(CAD software) really helps us to do our day to day work with accuracy and proficiency.

Choose materials that are easy to machine, finish, or treat. Maintain consistent wall thickness to ensure uniform post-processing results. Rounded edges are easier to machine and handle during post-processing. Consider the desired surface finish early in the design process.

Indeed a very important thing to keep in mind at every step of the design modelling process. When you have determined the manufacturing process for the part, it is best to design the part such that it would require the least post processing but at the same time not overcomplicating the production and assembly processes themselves. For example if you were to use material deposition printing such as FFF, it would be good to reduce extreme overhangs such that support struts are minimal if not eliminated. Eliminating supports in a 3D print reduces print time, material wastage, reduces issues of layer adhesion and delamination at extreme overhangs.

Always keep an open mind, and acknowledge that others may be able to see a better solution than you can, invite discussion and learn from other people and their designs. A great way to find examples online would of course be to google your specific application if not unique. If you are designing something with 3D printing, a huge resource would be online model sharing platforms such as Thingiverse, Printables, and MakerWorld. You might just find exactly what you need in some form or another, or you may get inspired by something completely different, but nonetheless it is a great way to seek creative solutions!

Additionally, collaboration between design and manufacturing teams is crucial to ensure that design choices align with the capabilities of the manufacturing processes.