Key principles.
Single biggest
Generous internal radii enable larger tools and faster cutting. Often 2-3× cost difference vs sharp corners.
Per feature
Tight tolerances only where function requires. Default ±0.1 mm. Save tighter for critical fits.
Process-friendly
6061 aluminum cheap and machinable. 7075 only when strength needed. Steel only when aluminum inadequate.
Avoid custom
Standard hole sizes, threads, bearing fits. Custom dimensions add tooling and time.
Minimize setups
Design for single-setup machining. Each new setup adds time and tolerance stack.
From bar/plate
Design to standard bar diameters, plate thicknesses. Saves material vs custom stock.
FAQ
Typically 20-50% on machining cost. Sometimes more for poorly-DFM designs.
Functional features must meet spec. Cosmetic features can use cheaper alternatives (powder coat vs anodize).
Always. Quote includes free DFM review. Implement suggestions or ignore — customer choice.
Yes. Low volume: minimize tool changes, fixturing. High volume: invest in custom tooling for cycle time reduction.
Each tighter tolerance class adds 30-100% feature cost. ±0.025 vs ±0.1 typically 2× cost.
Material 30-50% of part cost typically. Cheaper material grade saves directly. Premium material adds proportionally.
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