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Manufacturing process selection and Design for manufacturing

Mufaddal Rasheed

Design for manufacturing or DFM is a very important practical activity in Mechanical design engineering.

Converting concept  into designs which can be manufactured and ready for implementation is a key skill in product development.

This course attempts to cover the basics of designing for manufacturing including selecting a suitable process based on various criteria and designing for the process to reduce cost and improve ease of manufacturing .

Topics covered are

Read more

Design for manufacturing or DFM is a very important practical activity in Mechanical design engineering.

Converting concept  into designs which can be manufactured and ready for implementation is a key skill in product development.

This course attempts to cover the basics of designing for manufacturing including selecting a suitable process based on various criteria and designing for the process to reduce cost and improve ease of manufacturing .

Topics covered are

  1. Importance of Process selection

  2. Parameters and Criteria for selection

  3. Comparison of processes

  4. Process- Shape matrix

  5. Section wall thickness and Tolerance ranges

  6. Cost associated

  7. Part complexity and part cost

  8. Prototyping vs production

  9. Case studies in process selection

  10. Designing for Forging - principles and guidelines

  11. Designing for Casting - principles and guidelines

  12. Design for Injection Molding  - Principles and guidelines.

  13. Exercises to practice

The learning outcome of this course is to develop a strong basic comparative understanding of various processes and get started with designing as per certain processes to build DFM skills for mechanical design & product development.

Course will be best suitable for  Mechanical design engineers who want to level up their DFM knowledge and skills .

Enroll now

What's inside

Syllabus

Introduction
Importance of the process in Mechanical design engineering
Design approaches for process selection
Common processes
Read more
Process flow of a connecting rod
Casting processes
Forming processes
Moulding processes
Process selection
Selection process and Parameters which govern
Process- material compatibility
Shapes of Engineering parts
Process Shape Matrix
Section Thickness
Intro to Tolerance and Dimensional accuracy
Tolerance ranges of processes and surface roughness
Types of Costs
Cost model
Cost comparison of processes
Relative Cost between Process- Sand casting vs Die casting
Part complexity and part cost
Prototyping processes
3D printing and Injection Molding
Summary - Process selection
Case studies in process selection
Case study 1 - Steering column mount bracket
Case study 2 : Stepped shaft with keyway
Case study 3 : Shifter fork
Case study 4 : Steering knuckle
Case study 5 : Electronic Enclosure
Case study 6 : Brake line bracket
Exercise
Design for Manufacturing
Design for Manufacturing Intro
Why DFM is important
Design for Forging
Introduction to Forging
Impression Die forging Forging terminologies- Cross section
Generic Design principles in forging design
Fillet Radii and Draft angles
Web depth and wall thickness
Parting line
Grain Orientation and Affect of Parting Line
Side thrust force in Forging Dies
Ease of Forging - order of difficulty
Case study : Design for Forging
Exercises
Design for Casting
Introduction to Casting , parameters which govern quality
Generic Design principles in Casting design
Terms in Casting- Draft , core,
Importance of Parting line
Design features, poor and good
Reducing number of cores and Reducing complexity
Hot spots and Ribs
Summary - Design for Casting
Design for Injection Molding
Generic Design principles of Injection molding design
Parts of Injection Molding Die
Generic Design Rules applied , examples
Core strengthening
Gate location
Sinking and Warping Defects
Bosses and Gussets
Example
Test your knowledge
Bonus Section
Bonus Lecture

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Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Manufacturing process selection and Design for manufacturing with these activities:
Review Manufacturing Processes
Refresh your understanding of different manufacturing processes to better grasp the process selection criteria discussed in the course.
Browse courses on Manufacturing Processes
Show steps
  • Review notes from previous manufacturing or materials science courses.
  • Read articles or watch videos explaining common manufacturing processes.
  • Take a practice quiz on manufacturing process characteristics.
Review 'Manufacturing Engineering and Technology'
Study this book to gain a broader and deeper understanding of manufacturing processes and their applications.
View Manufacturing Engineering and Technology on Amazon
Show steps
  • Read the chapters related to casting, forging, and injection molding.
  • Take notes on key concepts and process parameters.
  • Compare the information in the book with the course materials.
DFM Analysis of a Simple Part
Apply DFM principles to analyze a simple part and identify potential improvements for manufacturability and cost reduction.
Show steps
  • Select a simple mechanical part (e.g., bracket, handle).
  • Identify the manufacturing process currently used or proposed.
  • Analyze the part design for manufacturability issues.
  • Propose design changes to improve manufacturability and reduce cost.
Four other activities
Expand to see all activities and additional details
Show all seven activities
Process Selection Comparison Chart
Create a visual chart comparing different manufacturing processes based on key parameters like cost, tolerance, and material compatibility.
Show steps
  • Choose the manufacturing processes to compare (e.g., casting, forging, machining).
  • Identify the key parameters for comparison (e.g., cost, tolerance, material).
  • Create a chart or table summarizing the comparison.
  • Present the chart visually using software or by hand.
Review 'Product Design for Manufacture and Assembly'
Study this book to learn about DFMA principles and apply them to product design.
View Product Design For Manufacture And Assembly,... on Amazon
Show steps
  • Read the chapters on DFMA principles and guidelines.
  • Work through the examples and case studies in the book.
  • Apply DFMA principles to your own product designs.
DFM Improvement Proposal
Develop a detailed proposal outlining DFM improvements for a specific product, including cost analysis and manufacturing considerations.
Show steps
  • Select a product or component for DFM analysis.
  • Identify potential DFM improvements based on course principles.
  • Quantify the cost savings and manufacturing benefits of the proposed changes.
  • Create a formal proposal with detailed drawings and analysis.
Explore CAD Software DFM Tools
Follow tutorials to learn how to use DFM tools within CAD software to analyze and optimize designs for manufacturability.
Show steps
  • Choose a CAD software package (e.g., SolidWorks, AutoCAD).
  • Find tutorials on DFM analysis within the software.
  • Practice using the DFM tools on sample designs.
  • Apply the DFM tools to your own product designs.

Career center

Learners who complete Manufacturing process selection and Design for manufacturing will develop knowledge and skills that may be useful to these careers:
Mechanical Design Engineer
Mechanical design engineers create and develop mechanical products and systems. This course helps those interested in becoming a mechanical design engineer by providing a strong foundation in design for manufacturing. The course covers the basics of designing for manufacturing, including how to select suitable processes based on various criteria. The course attempts to level up DFM knowledge and skills. For a mechanical design engineer, the course's specific modules on designing for forging, casting, and injection molding offer targeted guidance. The case studies included in the course, such as the shifter fork and steering knuckle studies, would be especially useful.
See salaries and explore the career path for Mechanical Design Engineer
Manufacturing Process Engineer
Manufacturing process engineers analyze and improve manufacturing processes to enhance efficiency and reduce costs. This course helps those interested in becoming a manufacturing process engineer by providing a deep dive into manufacturing process selection. The course covers parameters and criteria for selection and compares different processes. A manufacturing process engineer will find in this course a strong understanding of process material compatibility. The course's process shape matrix module will translate directly into professional utility.
See salaries and explore the career path for Manufacturing Process Engineer
Manufacturing Engineer
A manufacturing engineer focuses on improving manufacturing processes and ensuring efficient production. This course helps those interested in becoming a manufacturing engineer. The course covers selecting suitable processes based on various criteria, designing for the process to reduce cost, and improving ease of manufacturing. Manufacturing engineers can use what the course teaches about designing for forging, casting, and injection molding to optimize production methods. The inclusion of case studies of parts like steering column mount brackets, stepped shafts with keyways and shifter forks will provide real world working knowledge useful to the manufacturing engineer.
See salaries and explore the career path for Manufacturing Engineer
Design Engineer
Design engineers are involved in the planning and creation of various products and systems. This course helps prospective design engineers understand the principles of design for manufacturing. The course covers selecting processes and designing for cost reduction and ease of production. Topics like section wall thickness, tolerance ranges, and cost considerations enable design engineers to make informed decisions. The design engineer can further take advantage of this course by absorbing the case studies of parts such as electronic enclosures and brake line brackets.
See salaries and explore the career path for Design Engineer
Product Development Engineer
Product development engineers are responsible for taking a product from concept to market. This course helps those interested in becoming a product development engineer better understand how to convert concepts into manufacturable designs. This involves skills in process selection and design for manufacturing which are front and center in this course. The course's exploration of designing for forging, casting, and injection molding directly informs the product development engineer's design choices. Furthermore, the course material pertaining to wall thickness and tolerance ranges are of significant help to product development engineers.
See salaries and explore the career path for Product Development Engineer
Production Supervisor
Production supervisors oversee manufacturing operations and ensure production goals are met. The course teaches about cost models and part complexity in manufacturing. It also covers relative costs between processes, such as sand casting versus die casting. The course's exploration of prototyping versus production further informs supervisory decision making. The course attempts to cover the basics of designing for manufacturing including selecting a suitable process based on various criteria and designing for the process to reduce cost and improve ease of manufacturing.
See salaries and explore the career path for Production Supervisor
Process Technician
Process technicians monitor and control manufacturing processes to ensure quality and efficiency. The course addresses tolerances and dimensional accuracy in processes which aligns with the responsibilities of process technicians. Furthermore, the course provides a comparative understanding of various processes. The course covers common processes of casting, forming, and molding. Case studies of real world parts can provide the process technician with tangible context.
See salaries and explore the career path for Process Technician
Manufacturing Supervisor
Manufacturing supervisors are responsible for overseeing production and ensuring quality. The course covers different processes and includes a case study of process selections that align well with the responsibilities of manufacturing supervisors. This course may be useful to those interested in becoming a manufacturing supervisor. The course attempts to cover the basics of designing for manufacturing including selecting a suitable process based on various criteria and designing for the process to reduce cost and improve ease of manufacturing.
See salaries and explore the career path for Manufacturing Supervisor
Tooling Engineer
Tooling engineers design and develop the tools and equipment used in manufacturing processes. The course covers the basics of designing for manufacturing, including the selection of processes. This course may be useful to those interested in becoming a tooling engineer. The course attempts to cover the basics of designing for manufacturing including selecting a suitable process based on various criteria and designing for the process to reduce cost and improve ease of manufacturing . Topics covered are tolerances, costs, and part complexity.
See salaries and explore the career path for Tooling Engineer
Industrial Engineer
Industrial engineers improve efficiency within organizations by optimizing processes and systems. This course may be useful to those interested in becoming an industrial engineer. The course attempts to cover the basics of designing for manufacturing including selecting a suitable process based on various criteria and designing for the process to reduce cost and improve ease of manufacturing . Topics covered are tolerances, costs, and part complexity. The course's case studies may be useful to an industrial engineer.
See salaries and explore the career path for Industrial Engineer
Process Improvement Engineer
Process improvement engineers focus on optimizing processes to improve efficiency and reduce waste. This course may be useful to those interested in this career. This course covers the basics of designing for manufacturing. The course teaches about selecting a suitable process based on various criteria and designing for the process to reduce cost. Process improvement engineers could particularly find this course's discussion of process selection parameters and cost considerations to be useful.
See salaries and explore the career path for Process Improvement Engineer
CAD Designer
Computer aided design designers use software to create designs and models for products. This course may be useful to those interested in becoming a CAD designer because it covers the basics of designing for manufacturing, including selecting a suitable process based on various criteria. The course also discusses designing for forging, casting, and injection molding. CAD designers could gain better insight into the cost optimization of a design. The principles and guidelines of design are all vital for CAD designers.
See salaries and explore the career path for CAD Designer
Quality Engineer
Quality engineers ensure that products and processes meet certain standards. This course may be useful to those interested in becoming a quality engineer because it covers tolerance ranges of processes and surface roughness. This course attempts to cover the basics of designing for manufacturing including selecting a suitable process based on various criteria. The case studies in process selection, such as the steering column mount bracket and stepped shaft examples, would be applicable to the work of maintaining quality.
See salaries and explore the career path for Quality Engineer
Materials Engineer
Materials engineers research and develop materials for use in products and manufacturing. This course may be useful to those interested in becoming a materials engineer because it covers process-material compatibility. The course touches on different processes, including casting, forming, and molding, and the selection process. The course will help the materials engineer better understand manufacturing processes. The case studies of actual parts will bring material compatibility to life.
See salaries and explore the career path for Materials Engineer
Six Sigma Black Belt
Six Sigma Black Belts are change agents, project managers, and leaders. They must be able to demonstrate team leadership, understand team dynamics, and assign team members with actions, all while following a defined methodology. The course discusses cost models in depth. This is useful to those interested in becoming a Six Sigma Black Belt. The course attempts to cover the basics of designing for manufacturing including selecting a suitable process based on various criteria and designing for the process to reduce cost and improve ease of manufacturing .
See salaries and explore the career path for Six Sigma Black Belt

Reading list

We've selected two books that we think will supplement your learning. Use these to develop background knowledge, enrich your coursework, and gain a deeper understanding of the topics covered in Manufacturing process selection and Design for manufacturing.
Manufacturing Engineering and Technology
Save
Provides a comprehensive overview of various manufacturing processes, materials, and technologies. It serves as an excellent reference for understanding the underlying principles of manufacturing. It is particularly helpful for gaining a deeper understanding of the processes discussed in the course, such as casting, forging, and injection molding. This book is commonly used as a textbook in manufacturing engineering programs.
Manufacturing Engineering and Technology
Paperback
Check
Manufacturing Engineering and Technology
Kindle Edition
Check
Cover image
Product Design for Manufacture and Assembly, Third...
Save
Classic reference for Design for Manufacturing and Assembly (DFMA) principles. It provides detailed guidelines and methodologies for optimizing product designs for ease of manufacturing and assembly. It is particularly useful for understanding the quantitative aspects of DFM and for applying DFMA principles to real-world product designs. This book adds more depth to the course by providing a structured approach to DFM.
Product Design For Manufacture And Assembly, 3Rd...
Unknown Binding
$$$$

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Effort
3.5 total hours
Via
Udemy
Instructor
Mufaddal Rasheed
Language
English
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