DFM Studio // Automatic Manufacturability Assessment System
Fix Potential Manufacturability Issues
in Early Design Phase
It is almost impossible for even experienced engineers to design optimally considering the full manufacturability of the product.
DFM Studio aids design engineers during the design process by detecting potential manufacturability issues through geometry feature analysis. This helps eliminate the risk of spending hours or even days on engineering changes to fix issues raised by production engineers, and cause a delay on the entire production lead-time.
Automatic Evaluation to Save Engineers’ Time
Release design engineers from tedious, human eye manufacturability checks to facilitate value-added creative work.
Eliminate Rework to Shorten Lead-time
Minimize the risk of rework after dispatching the data to post processes, reducing lead-time.
Cost Reduction through Standardization
Reduce the manufacturing costs by avoiding complex tooling, standardizing the hole diameter, etc.
Assess Manufacturability through Geometric Analysis
DFM Studio is equipped with ready-to-use check criteria that cover all general manufacturing requirements.
Manufacturability is determined during the design phase, which means most manufacturability issues can be detected through CAD geometry/geometric (See Above Issue) analysis. Elysium has provided solutions to manufacturing requirements for numerous manufacturing industries including automotive, automotive parts, electronics, and precision machinery. DFM Studio accumulates our expertise derived from our decades of experience and is equipped with a pre-set check of criteria that cover all general manufacturing requirements developed by industry leaders.
Examples of Pre-set Check Criteria
For Plastic (Resin) Part
Wall Thickness of Product
Thick/thin areas in a CAD model can cause molding defects such as sink marks and insufficient fillings.
DFM Studio auto-measures the wall thickness, evaluates these against your thresholds, and shows the result in a list. Design engineers can then optimize the wall thickness without omissions.
Boss / Rib
It is important to ensure that it does not produce any other errors when fixing the draft angle errors. Specifically, it is essential to avoid having the boss wall thickness becoming too thick at the boss root when adding a draft from the boss tip or having the boss outer diameter becoming too small at the boss tip. These may cause issues such as sink marks and insufficient fillings respectively.
In DFM Studio, design engineers can explore options fixing relevant values and optimize the draft angle striking a balance between them.
Sharp edges on the product and sharp edges on the mold are common errors. However, they are critical errors that impact the mold cost, the product durability, and the product cost, and should be avoided unless necessary.
Other Check Criteria
- Tiny fillets (R)
- Thin parts (Mold)
- Draft angle
For Sheet Metal
Distance between Bend and Hole
In DFM Studio, design engineers can explore options fixing relevant values and optimize the draft angle striking a balance between them. To prevent this issue, it is effective to optimize the hole position according to the material, its thickness, and the distance to the bend.
Width of Narrow Area
Defects may occur when punching a narrow space, which results in the narrow bit coming out shorter than designed. To prevent this issue, it is effective to change the sheet metal thickness, widen the narrow area, and/or change the material.
Other Check Criteria
- Wall thickness
- Bends / Flanges / Hemings
Standardize Daily and Milestone Manufacturability Check
Run manufacturability check in DFM Studio (1) every day in out-of-office hours, and solve detected issues the next day securing manufacturability during the design process, and (2) as a milestone before dispatching a drawing to post processes to ensure that it complies with a company’s manufacturability standards. Daily checks contribute to minimizing rework at the final milestone check and increase efficiency for the entire process—from design to manufacturing.
Systematize the Know-how to Transmit to the Younger Generation
The succession of techniques is a common challenge in manufacturing industry. DFM Studio facilitates the systematization of skills and know-how for DFM—on the user interface of DFM Studio, articulate the purpose and reason for each check item and the instruction on how to fix detected errors, and set a hyperlink to related documents.
Manufacturability Check Backed by Sophisticated 3D Geometry Handling Technology
As an expert in 3D geometry handling technology, Elysium has been providing multi-CAx interoperability solutions to over 3,500 companies worldwide for three decades.
With that strong background, DFM Studio is developed utilizing the feature recognition capability that works even on the CAD data without the feature history. It automatically recognizes the area with the specified feature from the geometry, and evaluates the manufacturability on the input 3D CAD model.
Flexible Customization of Check Criteria to Meet Your Needs
Thresholds are set to values recommended based on Elysium’s expertise by default, and accommodate customization as required according to the material, etc.
Integration into Your System Landscapes to Enhance the Workflow
Not only as a desktop application, DFM Studio features batch processing as the ASFALIS Component, and also PDM integration using ASFALIS API option to run DFM Studio manufacturability check from the user interface of the PDM system.
Furthermore, the manufacturability check result report in Excel file has a potential for further utilization, e.g., quick quoting of the machining cost by the number of holes etc.
Aisin has successfully built their own system to verify the manufacturability by tuning up DFM Studio on the check criteria, check logic, evaluation threshold, visualization of the evaluation result, etc. flexibly to automate the manufacturability check process maintaining the accuracy from the past manual check.
Mazda Motor Corporation
Based on DFM Studio, Mazda Motor Corporation has custom-developed a functionality to detect the interference between car body parts, and ensure that an appropriate clearance is set between them.
What is DFM (Design for Manufacturability)?
Design for Manufacturability (also known as Design for Manufacturing) is the general engineering practice of designing products in such a way that they are easy to manufacture. The concept is to address and fix potential manufacturability issues in the design phase—the least expensive and least time-consuming phase compared to CAE analysis utilizing CAD design models or prototyping to assess the manufacturability of the design.
However, it is not realistic for design engineers to be well versed in manufacturing techniques, which are outside their area of expertise, and design in conformity with manufacturing requirements.
DFM Studio facilitates the systematization of your company’s own rules and expertise established by experienced engineers to achieve DFM. This will help release design engineers from manufacturability consideration and improve the efficiency throughout your entire manufacturing process.