MBD/MBE Are Becoming the New Standard in Manufacturing

Model-Based Definition (MBD) and Model-Based Enterprise (MBE) place the 3D model at the center of development. Unlike traditional processes—where information flows via documents and physical artifacts—MBD/MBE use 3D digital data for design, analysis, and verification to dramatically improve efficiency, quality, and traceability.

Over the past decade, Elysium has introduced solutions such as CAD Validation and Data Package to support global leaders through the early adoption and growth phases of MBD/MBE and the broader shift to digital manufacturing.

Because the 3D model is always at the core of model-based workflows, model quality is a key success factor. Elysium’s long-standing core competencies—CAD translation and Product Data Quality (PDQ) Check—are therefore essential to advancing MBD/MBE.

A New Solution to Support DFA

To further elevate model quality and fully realize the gains promised by MBD/MBE, Elysium continues to expand its verification capabilities. In September 2025, the new EX11.0 release of 3D-SUITE launched two additional model-verification functions:

These additions complement—and in some cases extend—conventional PDQ solutions that focus on eliminating data defects. For manufacturers advancing MBD/MBE, they are powerful additions that make 3D-SUITE an even more valuable platform.

This article highlights Design for Assembly (DFA)—a methodology that proactively considers assembly and disassembly in multi-part models. With DFX Analyzer, Elysium provides automated model checks to evaluate DFA completeness. By simulating real-world assembly challenges in the earliest design stages—without physical prototypes—DFA analysis truly embodies the spirit of MBD/MBE.

Challenges in Assembly and Their Root Causes

Without early assembly feasibility verification, manufacturers face:

  • Increased rework & quality issues
  • Higher downstream costs
  • Production delays & post-shipment maintenance problems

Common DFA Issues

  • Obstructions in screw-assembly paths prevent robotic assembly, forcing manual work.
  • Dimensional variances lead to misalignment during assembly.
  • Inadequate clearance between parts causes vibration-induced noise.

Many of these issues are only discovered at the prototyping stage, leading to expensive redesigns and delays. These problems can stem from lack of collaboration between design and production teams or insufficient worker expertise. However, even with skilled engineers, manual DFA checks are inherently flawed—undetected misalignments, interferences, or clearance issues often remain in CAD models without the designer’s awareness.

For example, unintended issues—such as misalignment from a changed hole position or new interferences after component repositioning—often remain in CAD models without the designer’s awareness. Designs that don’t reflect the actual assembly process (for example, blocked approach directions) also reduce efficiency for both people and robots.

Why DFA Automation is Essential

Even expert engineers can’t manually verify an entire CAD model with absolute accuracy; there are fundamental limits to human review. Skilled talent is scarce, and manual checks miss issues that surface at prototyping, triggering costly redesigns.

True digital transformation requires going beyond adopting IT tools to fully automating verification—making checks precise, repeatable, and efficient. That said, DFA automation is non-trivial because experienced engineers weigh multiple factors at once, such as:

  • Clearance checks—Is the spacing between components sufficient?
  • Interference detection—Is a contact intentional (fasteners) or unintentional (errors)?
  • Assembly direction constraints—Do obstructions prevent efficient assembly by robots or humans?

Some companies attempt to customize CAD systems with proprietary DFA check tools. However, these solutions require constant updates and maintenance, as CAD software regularly changes specifications.

In cases where a company switches CAD systems due to partner requirements or supplier changes, their entire custom DFA verification setup may become obsolete, forcing them to rebuild from scratch. As a result, many companies abandon DFA automation altogether before even attempting it.

Elysium’s DFA Solution: Combining Precision, Efficiency, and Automation

Elysium launched a next-generation DFA solution as part of 3D-SUITE. Our approach pairs proprietary geometry technology with official CAD-vendor APIs for accurate access to internal model data.

Why Elysium?

  • 40 years of expertise in 3D geometry handling
  • Official partnerships with major CAD vendors for precise API access
  • Industry-leading DFA logic that minimizes false positives

Unlike basic interference/clearance tools, Elysium’s DFA understands component relationships and filters out intentional contacts, e.g., fasteners.  Automated verification frees engineers from time-consuming inspections so they can focus on innovation and quality.

Two Ways To Implement DFA with Elysium

Elysium offers two flexible options:

  • Package software (3D-SUITE)
    An off-the-shelf DFA solution that works alongside CAD conversion and Product Data Quality (PDQ) verification, etc.
  • Geode SDK
    Launched in 2024, Geode SDK brings Elysium’s proven geometry recognition engine to developers as a powerful toolkit. Its applications range from custom DFX automation—covering DFA, DFM, and DFAS—to broader 3D data utilization systems. With tutorials and Python samples included, even engineers without prior 3D experience can confidently build tailored solutions.

By offering both ready-made software and customizable development tools, Elysium provides scalable DFA solutions for any manufacturing environment.

Precision Assembly Verification with Component Relationships in Mind

Effective DFA automation must distinguish intentional from unintentional contacts. If a tool flags every contact, engineers end up validating results manually—defeating the purpose of automation. Elysium’s geometry processing elevates machine judgement to experienced-engineer level by embedding real-world assembly logic, so only actual issues are flagged.
The solution is also highly configurable to company-specific standards and workflows. As CAD software evolves, Elysium keeps customized DFA scripts functional, preserving long-term usability and ROI.

Elysium’s DFX Solutions: Beyond DFA

Elysium also offers additional Design for X (DFX) solutions to optimize 3D CAD models:

Both are available within 3D-SUITE, enabling detection and correction of design issues before production.

How DFA Automation Works: A Bolt-fastening Example

Bolt Fastening Verification Workflow

  • Step 1: Identify Bolts
    3D-SUITE recognizes bolts within the CAD model based on the geometry and attributes of the assembly data.
  • Step 2: Assess Assembly Feasibility
    Using predefined rules and thresholds set by each company, the system automatically checks clearance, hole alignment, and fastening ease.
  • Step 3: Report Results
    An intuitive report lists findings so teams can systematically review every item—far more reliable than scanning color maps alone.

DFA Criteria Evaluated in 3D-SUITE

The following are verification items related to product assembly and disassembly.

  • Clearance
  • Hole connectivity
  • Axis misalignment
  • Standard diameter conformity
  • Through-hole accessibility
  • Underdriving prevention

etc.

Take the Next Step

DFA automation is no longer a luxury—it’s essential. With Elysium’s DFA capabilities in DFX Analyzer, manufacturers can automate error detection, improve workflow efficiency, and reduce design-to-production lead times. If you’re ready to strengthen quality and accelerate your MBE journey, contact Elysium to explore DFA automation.