Introduction
Great design isn’t just about function; it’s about how efficiently a part can be made. Implementing Design for Manufacturability (DFM) principles early in the product development phase can save you significant time and money. Here are three practical tips for engineers and designers.
1. Avoid Deep Pockets
Deep pockets require long-reach tools, which are prone to vibration (chatter). This limits the feed rate and increases machining time.
- Tip: Try to limit pocket depth to no more than 4 times the cavity width. If deeper pockets are necessary, consider splitting the part into two pieces that can be bolted together.
2. Standardize Hole Sizes
Every time a CNC machine changes tools, it costs time. If your design calls for five different drill sizes, the machine has to stop and change tools five times.
- Tip: Standardize hole diameters wherever possible. Using standard tap sizes also ensures easier sourcing of threads inserts later on.
3. Consider Internal Corner Radii
CNC end mills are round, meaning they cannot create sharp internal corners.
- Tip: Always specify a radius for internal vertical corners. A larger radius allows for a larger tool, which can remove material faster and more accurately than a tiny end mill trying to fit into a tight corner.