Keep Walls Consistent
Avoid abrupt thickness changes that can create porosity, shrinkage and uneven cooling.
ENGINEERING RESOURCES
Design Tips for
Better
Manufactured Parts
Explore practical design guidance for injection molding, CNC machining, die casting and sheet metal fabrication—from early concepts to production-ready parts.
- ✓ Design for Manufacturability
- ✓ Material & Process Selection
- ✓ Cost & Lead-Time Optimization
DESIGN WITH PRODUCTION IN MIND
Practical Design Guidance for Every Manufacturing Process
Explore process-specific recommendations that help improve manufacturability, control costs and prepare your parts for production.
FROM CAD TO PRODUCTION
Design details influence tooling, machining access, material flow, assembly and final part performance.
Injection Molding
Wall thickness, draft, ribs, bosses, gates and parting lines.
CNC Machining
Tool access, internal corners, tolerances, threads and materials.
Die Casting
Draft, wall transitions, ejector locations, fillets and flow.
Sheet Metal Fabrication
Bend radii, hole spacing, flanges, reliefs and tolerances.
01
DESIGN TIPS FOR
Injection MoldingDesign details influence filling, cooling, ejection and final part stability.
PLASTIC PART DESIGN
Design Plastic Parts for Consistent Molding
Well-designed molded parts fill more consistently, cool more evenly and release from the tool with less risk of distortion or visible defects.
Maintain Uniform Wall Thickness
Use balanced sections and gradual transitions to reduce sink, warpage and uneven cooling.
Add Appropriate Draft Angles
Provide sufficient draft based on feature depth, material and surface texture.
Design Ribs and Bosses Correctly
Size reinforcing features carefully to improve strength without creating thick sections.
Minimize Unnecessary Undercuts
Simplify side features where possible to reduce sliders, lifters and tooling complexity.
Consider Gates and Parting Lines
Review gate position and mold separation early to protect appearance and filling performance.
MACHINED PART DESIGN
Design CNC Parts for Efficient Machining
Practical CNC design decisions can improve tool access, reduce machining setups and help maintain consistent dimensional accuracy.
01
Add Practical Internal Corner Radii
Match internal radii to standard cutting tools instead of specifying sharp internal corners.
02
Provide Clear Tool Access
Keep critical surfaces and features accessible from practical machining directions.
03
Avoid Unnecessarily Deep Cavities
Reduce excessive depth-to-width ratios to limit tool deflection and extended machining time.
04
Use Tight Tolerances Selectively
Apply close tolerances only to dimensions that directly affect fit, function or assembly.
05
Standardize Holes and Threads
Use common drill sizes, thread standards and sufficient depth clearance whenever possible.
02
DESIGN TIPS FOR
CNC MachiningTool access and feature geometry directly influence machining time and cost.
03
DESIGN TIPS FOR
Die CastingCAST PART DESIGN
Design Die-Cast Parts for Reliable Production
Effective die-cast part design supports stable metal flow, consistent cooling, reliable ejection and better dimensional control.
Include Adequate Draft
Apply draft to walls, ribs and bosses to support reliable release from the die.
Use Fillets and Radii
Replace sharp transitions with suitable radii to improve flow and reduce local stress.
Optimize Ribs and Bosses
Support functional features without creating isolated heavy sections or hot spots.
Plan Parting, Ejection and Metal Flow
Consider parting lines, ejector locations, gates and overflow areas early to protect appearance and performance.
COMMON DIE-CAST MATERIALS
Aluminum Alloys
Zinc Alloys
FABRICATED PART DESIGN
Design Sheet Metal Parts for Accurate Forming
Good sheet metal design considers material thickness, bend behavior, feature spacing and assembly requirements before fabrication begins.
Use an Appropriate Bend Radius
Match the inside bend radius to material type, thickness and forming method.
Keep Holes Clear of Bend Lines
Maintain sufficient distance between holes, slots and bends to reduce distortion.
Add Bend Relief Where Needed
Use relief cuts near corners and flange intersections to prevent tearing or material buildup.
Design Practical Flanges
Provide enough flange length for accurate forming, fastening and final assembly.
Plan Joining and Assembly Early
Consider weld access, fasteners, hardware and alignment features during part design.
04
DESIGN TIPS FOR
Sheet Metal FabricationDESIGN CHECK
Forming-Ready Features
R
Bend Radius
D
Hole Distance
F
Flange Length
CORE DFM PRINCIPLES
Five Design Decisions That Shape Production
Before process-specific details are considered, these five decisions often have the greatest influence on manufacturability, part quality and overall production cost.
GEOMETRY
Simplify Where Possible
Remove unnecessary features and avoid geometry that creates difficult tooling, machining or assembly conditions.
WALL DESIGN
Keep Sections Consistent
Balanced wall sections support stable material flow, predictable cooling and more consistent part quality.
TOLERANCES
Specify What Matters
Apply tight tolerances only to functional features where they are genuinely required.
MATERIAL & PROCESS
Choose Them Together
Material properties, geometry, volume and performance requirements should guide process selection.
ASSEMBLY & FINISH
Plan Beyond the Part
Consider joining, secondary operations and surface finishing early in the design process.
The best time to resolve manufacturing risks is before tooling or production begins.
Request a Design ReviewENGINEERING DESIGN REVIEW
Is Your Design Ready for Production?
Send us your CAD files and project requirements. Our engineering team can review the design, material, tolerances and manufacturing process before production begins.
Manufacturability review
Material and process recommendations
Cost and lead-time evaluation
01 What is design for manufacturability?
Design for manufacturability, or DFM, is the process of reviewing a product design to ensure it can be manufactured reliably, efficiently and at an appropriate cost. It considers geometry, materials, tolerances, tooling, assembly and the selected manufacturing process.
02 When should a DFM review be completed?
A DFM review should ideally be completed before tooling, programming or production begins. Reviewing the design early makes it easier to correct potential issues without causing unnecessary delays or modification costs.
03 Which CAD file formats can I submit?
STEP, STP, IGES, X_T and SLDPRT files are commonly used for three-dimensional design review. Please also provide a PDF drawing when critical dimensions, tolerances, threads, finishes or inspection requirements need to be specified.
04 Can HordRT recommend the right manufacturing process?
Yes. Our engineering team can evaluate the geometry, material, production quantity, tolerances, surface finish and application before recommending a suitable manufacturing process.
05 How do tight tolerances affect manufacturing cost?
Tight tolerances may require additional machining operations, specialized equipment, slower production and more frequent inspection. They should mainly be applied to dimensions that directly affect function, fit or assembly.
06 Can a DFM review help reduce tooling costs?
Yes. Simplifying undercuts, improving draft, adjusting wall thickness and reviewing parting-line or ejection requirements can reduce tooling complexity and lower the risk of later modifications.
07 What information should I provide for a design review?
Please provide the 3D CAD file, technical drawing, preferred material, estimated production quantity, surface finish, application and any critical dimensional or functional requirements.
