Shaping for the Line

I’ve been wrapped up in the process known forebodingly to many as designing for manufacturing, also known as DFM. In collaboration with the engineers and technicians at HK AA Industrial, we spent some time revising the protractor into its final form fit for CNC machining.

Caption: The CEO of HK AA Industrial and I discussing design details.

More specifically, there are several issues that need to be addressed taking a part modeled and optimized for 3D printing into something that can be mass produced out of aluminum.

• Part strength. Given the persistent bending issues seen even on v6, do we need to increase or decrease the thickness with the different material?

• Surface finish. Parts made on a CNC are typically rough with sharp edges and tool marks. How do we want to cover these?

• Tooling limitations. Due to the undercuts of the internal dovetail, does the angle need to be standardized to fit a typical cutter?

• Handle attachment. How do we reliably produce and attach the handle to the sliders? Can we still use the screw design?

During my previous ventures with RFQs and inquiries to various suppliers, I had been told by multiple suppliers that my part was “too thin” and may be deformed in production:

Caption: A supplier I contacted with a RFQ warning me of the possibilities of deformation.

When it comes to all of these unsolved issues, your supplier will become your greatest resource. They are the ones who have the best understanding of what parts are makable and what parts are not. I strongly encourage anyone struggling with DFM to set up a voice or video call with the technicians at your supplier, where they can walk you through the necessary design changes.

My best advice? In Shaping for the Line, keep an open heart and an open mind.