Summary. Design for Manufacturability (DFM) is critical for achieving efficient, cost-effective results in custom metal fabrication and precision manufacturing. In the blog Design for Manufacturability: What Engineers Should Know Before Requesting a Quote, engineers will learn how to optimize their designs before reaching out for pricing. Common pitfalls—such as unclear drawings, overly tight tolerances, complex weldments, and nonstandard materials—can lead to inaccurate quotes and production delays. To ensure accurate quoting, CAD files should include complete geometry, material specifications, finish requirements, and tolerance data. Practical DFM strategies include selecting readily available materials, simplifying part geometry, reviewing and relaxing unnecessary tolerances, favoring fastening over welding when possible, and designing for easy assembly. Early collaboration with experienced fabricators like Mathison can help prevent costly revisions and reduce lead times. For complex parts, prototyping is also recommended to identify design issues upfront. A pre-quote checklist is provided to help engineers confirm design readiness. By embracing DFM early, engineers can expect more accurate quotes, fewer production issues, and better overall outcomes.

Full Blog:

Time, quality, and cost are the top considerations in custom metal fabrication and precision manufacturing.

Understanding and adhering to the principles of Design for Manufacturability (DFM) will contribute to a smooth, efficient, and cost-effective project experience for everyone.

If you are an engineer preparing to send a project out for quote, use this blog as your guide before doing so, so that the quote you receive will be accurate and thorough with every detail addressed.

Why DFM Matters

📏 Design for manufacturability is about optimizing your product’s design to ease fabrication, control costs, and ensure quality. For metal fabrication, factors to consider include material selection, dimensional tolerances, weld design, and assembly.

Integrating DFM principles early in the design phase will minimize revisions and lead times, and make your part, component or project easier to quote.

Common Pitfalls That Affect Quoting Accuracy

Before sending a project out for quote, be aware of several common pitfalls that can lead to inaccurate pricing or delays:

1️⃣ Unclear or Incomplete Drawings

Drawings that lack necessary dimensions, material specs, or finishing requirements make it difficult for fabricators to provide accurate quotes. Mathison is here to help you through this process if you need guidance or support.

For the best possible quoting process and experience, your CAD files (2D and 3D) need to include:

✅ Complete part geometry

✅ Tolerance specifications

✅ Material type and thickness

✅ Surface finish or coating requirements

✅ Notes on critical features

2️⃣ Overly Tight Tolerances

While tight tolerances are sometimes necessary, applying them to non-critical features will unnecessarily increase your lead time and drive up costs. Collaborate with Mathison Manufacturing early on to understand what tolerances are truly needed, and where, helping you identify only what’s truly necessary.

3️⃣ Complex Weldments

Overengineering for strength with weld-heavy designs that have hard-to-access joints will increase labor time and will likely require additional fixturing. (Fixturing is the process of securing a work piece in a precise and repeatable position during manufacturing or assembly operations.)

With weldments, more is not always better — not only do heavy weldments increase project costs, they carry distortion risks, especially in thin-gauge or cosmetic applications. Where possible, simplify weldments and ensure joint design allows for proper weld penetration and inspection access.

Mathison Manufacturing can recommend design alternatives like formed features or mechanical fasteners where appropriate.

4️⃣ Nonstandard Materials

Exotic or hard-to-source materials can delay quoting and extend lead times. If the application allows, select standard grades of stainless steel, carbon steel, or aluminum that are commonly stocked.

If the part or component you need is for a unique application or special use, contact us to discuss materials you are interested in using and their availability.

Practical DFM Considerations for Fabrication Projects

Here are several factors to consider when preparing your project for a quote:

1️⃣ Material Selection

Whenever possible, choose materials that are compatible with your application and those most readily available. Metals such as 304 and 316 stainless steel, cold-rolled steel, and aluminum 5052 or 6061 are standard in many fabrication shops.

2️⃣ Part Geometry

Avoid overly intricate geometries that require multiple setups or special tooling. Design features should be easy to access and fabricate with common machinery like press brakes, lasers, and CNC machines. Also consider that excessive tolerances also impact inspection time and tooling wear, leading to additional time and cost.

3️⃣ Fastening vs. Welding

Determine whether parts are best joined using welds, fasteners, or a combination. Welds may provide a cleaner look and stronger joint, but screws or rivets allow for easier disassembly. Consider cost, strength, and assembly time. This is another area where the team at Mathison Manufacturing can offer ideas and recommendations.

4️⃣ Tolerance Review

Work with us to review tolerances early on. If a tolerance can be opened without affecting function, doing so can simplify the manufacturing process and reduce inspection time. This leads to cost savings and reduced lead times.

5️⃣ Assembly Considerations

When designing parts, keep the assembly process in mind. Clearly show how components fit together, and consider stack-up tolerances that could affect alignment. (Stack-up tolerances are the cumulative effects of individual component tolerances when assembled together, potentially leading to a larger overall variation in the final product.)

If subassemblies are involved, include exploded views or build instructions.

6️⃣ The Role of Collaboration

Effective design for manufacturability isn’t a solo effort. Engage with Mathison Manufacturing early in your design process to get input on feasibility, cost-saving opportunities, and process capabilities. As an experienced fabrication partner, we will provide valuable insights on material handling, press brake forming limits, laser cutting tolerances, and other process-specific details.

Benefits of a DFM-Focused Approach

By considering manufacturability before sending your project out for a quote, you’ll benefit in several ways:

👉 More accurate and competitive quotes

👉 Fewer design iterations

👉 Faster production ramp-up

👉 Improved part quality and consistency

A DFM-focused design also reduces the risk of production issues with part alignment during assembly (fit-up problems), warping from weld stress, or difficulty in achieving specified finishes. These are critical factors in industries where tight-tolerance fabrication and assembly precision are required.

Prototyping and Feedback

For complex or new products, prototyping can be an effective step before full production. A physical prototype allows you and Mathison to identify and resolve any issues in design, tolerances, or materials. This upfront investment often pays off by reducing rework, scrap, and delays.

Your Pre-Quote Checklist:

Before sending your design out for quote…

✅ Are all drawings complete with dimensions and material specs?

✅ Have you reviewed and justified all tight tolerances?

✅ Is the material readily available?

✅ Are welding or assembly methods clearly defined?

✅ Have you considered manufacturing input or had a DFM review?

Of course, if you need consultation or guidance in any of these areas, reach out to us early on so we can ensure your project is completed as efficiently and cost-effectively as possible, while meeting the highest standards of function, durability, and aesthetics. We’re here to help bring your vision to life.

💬 Final Thoughts

Good design practice is much more than thinking through how something works – it also takes into consideration how parts and components are made.

By integrating design for manufacturability early on, our engineers can streamline the quoting process and set the table for efficient, cost-effective production. Taking time to refine a design before sending it out for quote leads to better outcomes for everyone involved—from engineering to production to the end user.

About Mathison Manufacturing

Founded in 1959, Mathison Manufacturing is a trusted partner in precision contract manufacturing, specializing in tight-tolerance sheet metal fabrication, electromechanical assemblies, and complex, high-end solutions. Known for exceptional craftsmanship, responsive service, and a customer-first mindset, Mathison is dedicated to delivering quality products and building lasting partnerships that help customers grow.

Let’s work together on your next project! Contact us today!