Design for Manufacturability: 4 Design Choices to Lower Your Machining Costs
At Area Tool & Manufacturing, we aim to be a true partner in manufacturing, not just a job shop. Some customers may come to us expecting only a precision machine shop that can produce a part to specifications, but we always search for ways to go above and beyond by helping you reduce costs and shorten lead times for your project.
In particular, we’ve found that simple conversations around design for manufacturability (DFM) or design for assembly (DFA) can lead to significant savings for customers. To help you in your next project, we’re sharing four key cost drivers we often help customers optimize.
1. When You Have Multiple Material Options, Opt for the Easiest to Machine
Material choice is a major factor in machinability, ultimately impacting your project’s cost. When machinists struggle with a certain material, production time and waste may increase, affecting your bottom line.
Engineers often choose materials based on end-use properties like corrosion resistance or magnetic behavior, but they may not realize that multiple materials offer similar performance with drastically different machinability.
We’re always happy to offer design for manufacturability guidance on materials that may allow for faster precision machining while saving you money. Some common suggestions include:
Is Plastic Really Cheaper Than Aluminum?
Plastic may seem like a cost-saving choice, but it’s often less stable and more difficult to machine, especially for tight tolerances or fine features. Aluminum costs more upfront, but a project’s overall cost may be lower with aluminum because it is faster to machine and more dimensionally stable.
Not All 300 (Or 400) Series Stainless Is Equal
Many designers may only require a 300 series stainless steel, choosing 303 because it’s a well-known option. Yet 304 is significantly easier to machine while offering similar performance benefits. Similarly, in the 400 series, we often recommend switching from 420 to 440 for better machining stability.
2. Design Around Standard Options in Materials, Tooling, and Hardware
We sometimes receive designs with specifications that are common in international manufacturing but hard to source in America. We see it in a variety of cases—a European thread, for instance, or an alloy that’s hard to obtain in the United States.
When feasible, we recommend designing around standard domestic options. While we can source obscure materials or find a solution for unique requirements, it will typically add costs and lead time to your projects.
3. Avoid Tight Tolerances Whenever Possible
Our team has been making parts for many years, and they have an excellent sense for tolerances that may be tighter than necessary for the function of the part. Tight tolerances can slow down machining, require more tool changes, and increase inspection time, ultimately raising both the time and cost of your project.
We’ll always meet your print, but when we see a chance to open a tolerance without affecting performance, we’ll ask. It’s just one of the ways we work to reduce unnecessary costs for our customers and give transparency into the various cost drivers of parts.
4. Choose Cost-Effective Finishing Options
Finishing can significantly impact cost and turnaround time. Through our network of local vendors, we have access to a range of plating and coating options that balance performance and affordability.
In one case, a customer requested a specific Teflon coating that required the part to be shipped thousands of miles, adding cost, lead time, and risk. We told them about our in-house Cerakote coating services that provided equivalent performance. They were happy to make the change, which ultimately allowed us greater control over the end product and faster delivery.
Let Us Make Your Next Project Easier
We don’t just machine parts, we find opportunities to improve your bottom line. Whether you need 5-axis machining or wire EDM services, partnering with Area Tool is always a better experience.
Request a quote today to learn how our Pennsylvania tool and die shop can help you optimize your next project!
