Skip to main content

Module 3 — Design for Manufacture

Objective: release parts ready for fabrication.

Prereqs: Subassembly models complete.

Steps

Apply correct hole sizes/tolerances for the process; select hardware and materials.
Create drawings and DXF/STEP exports; include BOM and notes.
Use calculators to verify loads and ratios where applicable.
Add manufacturing notes (deburr, tap sizes, countersink depths).
Provide flat patterns for sheet parts and mark bend lines/K-factors if needed.

Deliverables

Drawing pack (PDF + DXF/STEP) with BOM, materials, thickness, finishes, and callouts.
CAM-ready exports and a short fab checklist.

Resources

WCP calculators: wcproducts.com/pages/calculators
JVN calculators: chiefdelphi.com/t/paper-jvn-mechanical-design-calculator/153831
REV MAX guide (belts/chains): docs.revrobotics.com/maxguide/

Instructions (numbered)

Set hole sizes/tolerances for the process (CNC, manual, print); choose hardware/materials.
Add manufacturing notes (deburr, tap sizes, countersinks, bend lines/K-factors).
Generate drawings + DXF/STEP; include BOM, materials, thickness, finishes, callouts.
Verify loads/ratios with calculators where applicable.
Assemble fab checklist; review with manufacturing lead.

Example

Plate: 0.125" 6061, #10 clearance 0.201", 1/4-20 tapped holes marked, deburr all edges, bend line with K-factor 0.4, DXF/STEP attached.

Best practices

Tailor hole/tolerance to process and hardware; avoid over-tolerancing.
Include all notes on drawings to prevent shop guessing.
Keep CAM-ready exports in a known folder and versioned.

Common mistakes

Missing tap/countersink notes; wrong hole sizes.
No bend data; wrong K-factor.
BOM omissions; unlinked exports.

Checklist

Recommended tools

Drawing templates, DXF/STEP export, WCP/JVN calculators, bend calculators.

Sample log (template)

Date:
Parts released:
Notes added:
Exports location:
Issues:

Photos/diagrams

[Placeholder: drawing snapshot with notes/callouts]