As a young engineer years ago, a major component of engineering that I didn’t appreciate was the importance of open communication with manufacturers. I think a lot of engineers have this problem even long into their careers. Learning to ask manufacturing questions is a critical component of developing cost-effective designs; it’s just one component of a concept known as Design for Manufacturability (DFM).
I had an interaction this morning with a supplier that brought this point home and provoked me to write this. I jumped on a call with a manufacturer to discuss a project he quoted around $20,000+. Through open dialog and strategic questioning, I was able to make very minor tweaks to the design and he expects the cost to go down by by ~$3,000+. It all happened because I needed to learn more about what made his manufacturing process difficult. It wasn’t at all about talking him down on price; it was about understanding what made my parts difficult for him to make.
Engaging with manufacturers is enlightening. It provides insights into the complexities of various production processes, from metal fabrication to precision machining to plastic injection molding. I am way more effective as a design engineer because I asked LOTs of questions. Even after 20+ years, I am still learning.
This practice of DFM—of actively seeking collaboration with those who manufacture our designs—serves a dual purpose: it not only ensures our projects are more economically viable, but it also enriches our professional expertise. In essence, DFM is not just about making things cheaper; it’s about making things more efficiently for everyone involved.