In today’s fast-paced world, the need for efficient and innovative design solutions has never been greater.
Whether you’re an engineer, a manufacturing professional, or part of a business that needs custom metal parts, optimizing your product design is crucial for reducing costs, improving performance, and accelerating time to market.
Luckily, there are various design optimization strategies that will not only help enhance the functionality and aesthetics of any product, but also ensure that it can be manufactured and assembled with minimal issues.
In this article, we’ll explore four essential design optimization methods that anyone involved with the manufacturing of custom metal parts should be familiar with.
Let’s get started.
Generative design is an advanced design approach that leverages algorithms and artificial intelligence (AI) to explore a seemingly unlimited number of possible design solutions.
With the help of generative design software, designers can input specific constraints and requirements (e.g. material type, manufacturing methods, and performance criteria) to get the most optimized design possible.
This is very important in the realm of manufacturing, as it allows designers and manufacturers to produce more innovative and unexpected solutions that a human designer might not conceive independently.
In the context of metal parts manufacturing, however, generative design can be used to derive additional benefits.
Metal components often require a balance between strength, weight, and material usage.
These are parameters that can be adjusted using generative design software.
Take, for example, cost savings.
Through the use of the generative design process and the software associated with it, manufacturers can create highly efficient designs for metal parts that maximize performance while also minimizing material usage.
This results in an overall reduction in both weight and production costs.
For instance, Airbus used generative design to create a new partition for its A320 aircraft.
They were able to reduce the weight of the partition by 45% while maintaining the necessary strength and functionality.
Furthermore, this design optimization method aids in supporting sustainability goals through the optimization of material usage.
It helps cut down on material costs and the environmental impact associated with metal production and processing.
French sporting goods company Decathlon demonstrated that using generative design for a metal bike frame could reduce material waste when compared to traditional design methods.
As you can see, the use of generative design principles allows manufacturers and designers to harness the power of algorithms and AI to create numerous design alternatives that meet specific constraints and requirements.
This is a proven strategy that leads to lighter, stronger, and more cost-effective products and components.
Topology optimization is a computational design method that optimizes material layout within a given design space for a set of performance targets.
It does so by determining the best distribution of material, which ultimately helps create components that are both lightweight and structurally sound.
Topology optimization is particularly useful in metal parts manufacturing, where achieving the perfect balance between strength and weight is crucial.
This design optimization method starts with defining the design space and the loads and constraints the part will encounter during its use.
It then utilizes optimization models—design algorithms—to iterate through numerous possibilities and find the optimal material distribution that maintains structural integrity while minimizing weight.
The results of this process are parts that are not only lighter but also often exhibit improved performance characteristics, such as enhanced durability and reduced material fatigue.
Airbus applies topology optimization to redesign lighter-weight cabin brackets with the necessary strength and rigidity needed for safe flight.
General Motors, on the other hand, uses topology optimization to develop optimized auto parts that are 40% lighter and 20% stronger than their predecessor.
Since it can optimize material distribution within a component to achieve the best possible balance between weight and strength, topology optimization has found favor and is considered one of the most important design optimization methods in large industries like aerospace and automotive.
Design for Manufacturing (DFM) offers one of the most systematic and easiest approaches to designing products.
In fact, its primary objective is to simplify the design of parts and products so they can be manufactured quickly and cost-effectively, without compromising on quality in the process.
This process can achieve such multi-faceted benefits due to its ability to analyze various manufacturing constraints and capabilities during the design phase.
The DFM process typically involves several key elements, including the ones outlined in the table below.
| Material Selection | Considering factors such as cost, availability, and material properties to ensure the material is suitable for the intended manufacturing processes. |
| Process Selection | Identifying the most appropriate manufacturing process (e.g., casting, forging, machining) based on the design requirements and material properties. |
| Design Simplification | Simplifying the design by reducing the number of components, minimizing complex features, and avoiding unnecessary intricacies. |
| Tolerance and Fit | Setting appropriate tolerances and fits to ensure that parts can be manufactured accurately and assembled easily. |
| Tooling and Fixtures | Designing parts with standard tooling and fixtures in mind to reduce the need for custom tools, which can be expensive and time-consuming to produce. |
According to the National Institute of Standards and Technology (NIST), implementing DFM principles can reduce production costs and decrease time-to-market by a substantial margin.
Therefore, it can be concluded that the DFM method would be particularly useful for metal parts projects that must be performed with manufacturability in mind.
A design optimization process that allows for the consideration of material and process selection, as well as design simplification is the perfect solution for such requirements.
The design for assembly (DFA) method is, as its name suggests, focused on ease of assembly.
The main goal is to simplify the assembly process, reduce the number of parts, and minimize assembly time and costs.
DFA employs careful consideration of assembly constraints and processes during the design phase to ensure that products can be assembled quickly, efficiently, and with minimal errors during the manufacturing process.
DFA is particularly relevant in metal parts manufacturing.
Namely, it helps optimize the assembly processes by making sure that components are designed for straightforward and efficient assembly.
The specific steps employed by this design method are as follows:
1. Minimizing Part Count: Reducing the number of components in a product to simplify the assembly process.
2. Standardizing Parts: Using standard, interchangeable parts whenever possible to simplify the assembly process and reduce the need for custom components.
3. Designing for Easy Handling and Orientation: Ensuring that parts are easy to handle, orient, and position during assembly.
4. Simplifying Fastening Methods: Using simple and efficient fastening methods, such as snap-fits or self-fastening components, to reduce assembly time and complexity.
5. Facilitating Modular Design: Designing products in a modular fashion for pre-assembly and sub-assemblies.
Opting for DFA has been particularly useful for the tech giant Apple.
Designing components that are easy to assemble and that reduce the number of screws and connectors required has allowed them to significantly streamline its product design and manufacturing process.
All in all, the Design for Assembly (DFA) method should be employed by businesses looking to optimize their metal parts and products for easy and efficient assembly.
The method’s ability to minimize part count, standardize parts, design for easy handling and orientation, simplify fastening methods, and facilitate modular design makes it the perfect design option for such lofty goals.
The four essential design optimization methods mentioned in this guide can significantly enhance the efficiency and effectiveness of metal parts manufacturing.
They allow manufacturers and product designers to redesign lighter, stronger, and more cost-effective metal parts while streamlining production and reducing manufacturing costs at the same time.
However, not all projects will require the use of every design methodology.
That is why it is essential to consult with an experienced metal parts manufacturer who understands these design principles and the most prominent manufacturing processes that work well with them.
They can help you choose the most suitable design optimization methods for your specific project and ensure the best possible outcome for your metal components and products.
From a contract manufacturing firm, BuntyLLC evolved into a full service custom machined, forged and cast metal parts fabrication enterprise. We supply global solutions from our headquarters in Greenville, South Carolina.
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