4 Common Mistakes to Avoid When Designing for Manufacturing

Designing products for manufacturing is more than just creating a functional prototype—it's about thinking ahead and considering how each part will be made. A well-thought-out design can save time, reduce costs, and prevent costly rework down the line. At CAMM Metals, we use advanced CAD tools to provide real-time feedback on machined parts, but even with technology, some design decisions can still lead to complications. Here are some common mistakes that can be easily avoided when designing for manufacturing—helping you streamline the process and improve your product’s overall quality.

Not Understanding Machine Capabilities

One of the most frequent mistakes we see is when designers don’t take the time to understand the machines their parts will be manufactured on. Every fabrication shop has its own set of tools and limitations, and knowing these upfront can make a big difference in your design. For example, if your part requires deep bends, you need to know the maximum bend radius of the sheet metal brake available at the facility. Similarly, for CNC machining, understanding machine tolerances can help you avoid unnecessary specifications that increase cost. Being aware of what’s possible from the start can lead to better results and fewer delays.

Including Complex or Hard-to-Machine Features

Some features are simply harder to machine than others. Thin walls, deep holes, and intricate 3D surfaces can all add complexity and time to the manufacturing process. For instance, thin-walled components may break during milling due to vibration, while deep threaded holes might require long-reach taps that aren’t always on hand. These challenges can be avoided by simplifying your design where possible or working closely with your manufacturer to find alternatives. The goal is to create a design that is both functional and easy to produce.

Lack of Clear Part Specifications

When working with a new manufacturer, it’s important to provide as much detail as possible. Engineering drawings are not just for aesthetics—they contain critical information like material type, surface finish, and tolerance requirements. If you only say “aluminum,” you’re leaving out key details that could affect the final outcome. Do you need a certified material? What about a specific surface treatment or coating? Providing this level of detail ensures that the manufacturer can produce exactly what you need, without guesswork.

Using Non-Standard Sizes and Materials

While it might seem like a small choice, using non-standard materials or feature sizes can complicate the manufacturing process. Custom sizes often require extra setup time, additional tooling, or even special orders. By using standard dimensions and commonly available materials, you can reduce lead times and costs. Also, sticking to standard tap and drill sizes makes it easier for manufacturers to work with your design, as they are more likely to have the necessary tools in stock.

Final Thoughts

Designing for manufacturing is an ongoing process that requires collaboration, communication, and a bit of forward-thinking. While this list covers some of the most common pitfalls, there’s always more to learn. Remember, your manufacturer is an expert in their field—don’t hesitate to ask questions or seek their input. A strong partnership built on trust and clear communication can lead to better designs, faster production, and a more successful product launch.

CAMM Metals | CT Metal Fabricator

Choosing the right metal fabrication partner is essential to the success of your project. At CAMM Metals, we bring years of experience and expertise to every job, ensuring high-quality results and cost-effective solutions. Whether you're working on a small prototype or a large-scale production run, we're here to support you from design to delivery. Let us help you turn your vision into reality.

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