Many companies see manufacturing as a straightforward process: send a design, get a finished part back. For complicated projects, though, this simple approach often results in missed opportunities for a better outcome. The difference between a part that simply works and a product that is truly competitive and cost-effective is often made in the planning phases, well before any material is cut.
That’s why professional engineering consulting services, like those from our WessDel team, are just as important as the machining process itself.
Connecting the Design Intent with Production Reality
A great idea developed in R&D doesn’t always transfer perfectly to the manufacturing floor. A design may look ideal in a CAD program, but create significant problems related to material properties, tool access, or how the part must be held during machining. Partnering with a manufacturer for early-stage consultation effectively connects the design intent with the reality of high-volume production.
By reviewing designs early, engineers can pinpoint potential problems with tolerances or geometries that could unnecessarily increase costs. This early intervention allows your team to adjust specifications while the design is still flexible, avoiding expensive revisions later on. This changes the focus from just producing a part to producing that part efficiently and reliably.
Design for Manufacturing and Assembly (DFMA)
A core element of our consulting service is “Design for Manufacturing and Assembly,” or DFMA. This systematic approach aims to simplify the product structure to streamline both fabrication and final assembly times. We use advanced simulation and analysis tools during this stage to predict how components will behave both during the manufacturing process and in their final application.
Our engineering team focuses on several essential areas during a DFMA review:
- Material Evaluation:Assessing material options to achieve the optimal balance between cost, performance, and machinability, especially when working with specialized or exotic alloys.
- Part Reduction:Identifying opportunities to decrease the total number of unique parts, which simplifies the final assembly process and improves structural integrity.
- Geometry Analysis:Reviewing the shape and features to ensure that all areas are accessible for tooling and confirming that required tolerances can be maintained consistently.
Establishing Reliable Processes for Consistency
Once a design is optimized, the main task becomes ensuring the process is repeatable. In regulated sectors like aerospace and defense, producing one excellent prototype is insufficient, and the ability to produce thousands of parts with consistent precision is mandatory. Effective engineering consulting means developing robust manufacturing processes that can withstand rigorous quality checks.
This phase includes creating custom fixturing and tooling strategies specifically designed for the component’s geometry, ensuring the part is held securely without introducing stress that could distort the final product. We establish essential metrology and inspection protocols. These quality verification steps are fully integrated into the production workflow, guaranteeing that every component adheres to strict industry standards.
Partner with WessDel for Integrated Engineering Support
Choosing the right manufacturing partner means selecting a team that provides deep engineering support, not just manufacturing execution. With five decades of industry experience, WessDel delivers the comprehensive expertise needed to guide your project from the initial concept phase through to validated, full-scale production.
Contact WessDel online today or call (408) 496-6822 to discuss how our engineering consulting services can help you streamline processes.