DESIGN FOR MANUFACTURE
Mass Production
Once prototyping and testing are complete, the product is ready to transition into mass production. At Smallfry, we help clients reach this stage with confidence by validating designs through iterative product prototyping and testing, reducing risk before manufacturing begins.
Using a range of rapid prototyping techniques, we refine both the product and the manufacturing approach. This allows potential issues to be identified early and ensures the design is optimised for design for manufacture (DFM), enabling a smoother and more efficient transition into production.
Integrating design into production is an iterative and collaborative process. As an industrial design consultancy, we work closely with clients and manufacturing partners to ensure products meet quality, performance, and regulatory requirements while remaining commercially viable and aligned with user needs. By combining prototyping, testing, and design for manufacture, we help transform product ideas into production-ready solutions. This attention to detail not only supports a successful product launch but also helps our clients stay competitive in fast-moving markets.
Supplier Sourcing
Selecting the right suppliers is a key part of design for manufacture. At Smallfry, we help clients identify and evaluate manufacturing partners based on cost, quality, capability, and lead times, ensuring they align with both technical and commercial requirements.
By supporting supplier selection early in development, we help build strong manufacturing relationships, reduce risk, and set products up for successful production.
Detail Design Development
Detail design development involves refining the product to ensure efficient and effective production. At Smallfry, this stage focuses on translating a high-level concept into a detailed design ready for volume manufacture, considering factors such as material selection, manufacturing processes, and assembly methods.
During this phase, specifications are reviewed, subassemblies are defined, and components are checked and refined. Individual parts are finalised, technical calculations are completed, and conformity with relevant standards is ensured. Supporting documentation is prepared and reviewed throughout.
The goal is to deliver a design that meets functional and aesthetic requirements while remaining efficient and practical to manufacture.
3D Production Data
In addition to 2D drawings, the production process also requires accurate 3D data. At Smallfry, we provide detailed CAD files that support the creation of moulds, tooling, and other manufacturing components.
This data plays a crucial role in accurately representing the design and maintaining consistency across all parts of the product. It also supports quality control during production, allowing manufacturers to use specialised software to interpret the 3D data and produce physical components in line with the approved design.
2D Engineering Drawings
2D engineering drawings are technical documents that provide detailed information about the product design and individual component parts. At Smallfry, these drawings are developed primarily as component control drawings to support accurate production.
While most physical part specifications are contained within 3D CAD data files, 2D drawings highlight the critical dimensions, tolerances, and key specifications required to control manufacturing. They act as a universal communication tool between designers, toolmakers, and manufacturers, ensuring everyone is aligned when producing parts that meet agreed quality standards.
Quotation Packages & Bill of Materials
Quotation packages provide detailed information about a product’s design and specifications, enabling manufacturers to accurately cost production. At Smallfry, these packages typically include 2D engineering drawings, 3D production data, and a Bill of Materials (BOM), helping clients obtain reliable and competitive quotations from manufacturing partners.
The BOM is a comprehensive list of all the components, subassemblies, and materials needed to manufacture a product. It includes not only the item names but also their part numbers, quantities, and descriptions. The BOM is essential for tracking the different parts during the production process and ensuring that all necessary components are available. It also helps to identify potential cost-saving opportunities by analysing the materials used in the product.
Standard Operating Procedures
Standard Operating Procedures (SOPs) provide clear instructions on how specific tasks should be carried out within the manufacturing process. They help ensure consistency and quality in production by outlining the required steps, materials, and equipment for each task.
At Smallfry, SOPs support reliable manufacturing by helping ensure processes are clearly defined and repeatable. They can be reviewed and refined over time to improve efficiency and reduce the risk of errors during production.
Production Support
Design for manufacture also involves providing support during the production phase. At Smallfry, this can include troubleshooting manufacturing issues, clarifying design specifications, and making adjustments where needed to support successful production.
Providing production support helps maintain strong working relationships with manufacturing partners and ensures the final product meets the required quality standards without compromising performance, features, or customer benefits.
Initial Tooling Trials & Parts Approval
Before mass production can begin, initial tooling trials and parts approval are necessary. At Smallfry, this involves testing the tools and equipment used in production, as well as producing a small batch of parts to ensure they meet the required specifications. Any issues or adjustments needed are addressed at this stage to avoid potential problems during mass production.
Design for manufacture encompasses various stages and elements, all working together to create a high-quality product at an efficient cost. By considering these factors during the design process, manufacturers can produce products that not only meet functional and aesthetic requirements but are also easily and cost-effectively produced.
