From CAD to Reality: Navigating the Product Development Process

Developing a product from computer-aided design (CAD) to manufacturing a finished good can be challenging. From budget considerations to product quality and deadlines, creating an efficient product development process is important.

This guide will outline the key stages of product development in the manufacturing industry. We cover how to design for manufacturability, use prototypes effectively, and implement best practices for engineering collaboration between designers and fabricators. 

What Is the Product Development Process in Manufacturing?

The product development process for a manufactured good usually follows these stages:

1. Developing a concept
2. Turning the concept into a CAD design with manufacturability in mind
3. Optimizing the CAD design for effective fabrication
4. Using prototypes to test the product and how the CAD design translates into a finished product
5. Stepping up production from single prototypes to full production runs

When you’re developing a physical product, there is a lot of time and cost associated with changing molds, tooling or assembling factory lines to incorporate design changes. This makes the initial concept and CAD design stages vital for ensuring your initial prototypes are as close to your finished product as possible, reducing material wastage and the costs of changing your production setup.

Collaboration between the designers and fabricators is also needed to tweak the CAD designs and choose the right materials and processes to create a high-quality final product. 

Create Strong Foundations in Product Design

Before manufacturing can begin, you need a strong concept in the initial design phase that preempts any obstacles and fulfills your product needs. Some of the key planning considerations include:

• Set clear objectives: Consider the most important aspects of your product and its necessary functions, and set a target cost.
• Consider all stakeholders: Your concept should incorporate input from various stakeholders, from designers to fabricators, as well as the marketing team and your end user. Each stakeholder can use their expertise to find any limitations or flaws in your product development early on, so you can solve them at the design stage. 
• Design for manufacturability: Your product should follow best design practices, including reducing the number of components or using standard parts to simplify the manufacturing process, speed up production and reduce overall costs. 

How to Optimize CAD Designs

Once you’ve refined your concept, the next stage is to create your CAD design. Whether you’re manufacturing the product in-house or working with a manufacturing partner, you need to optimize your CAD drawings. 

The best practices for CAD drawings include:

• Simplify the geometry of your product to allow for easier manufacturing. 
• Ensure your model is solid and complete.
• Use standard parts. 

You’ll also need to consider the various CAD file formats. Choosing the best file format will depend on the type of product you’re manufacturing and the machines you or your manufacturing partner use.

You could use a neutral file format like STEP, IGES or JT, which can be used across CAD software. Other file formats, like DWG, are native and can only be used within the original CAD software, unless you convert them. Confirm the best file format with your manufacturing team or partner to carry over designs seamlessly. 

Additionally, consider your design’s tolerances to ensure that any parts fit together properly, even as variations occur during manufacturing. ASME Y14.5-2018 sets a standard for this with specific guidance and requirements for drawings.

A key part of this is the symbolic language called Geometric Dimensioning and Tolerancing (GD&T), which specifies the tolerance and how to measure any variations. This allows for uniformity across the manufacturing process, and it sets the level of precision to which you wish to manufacture your product for quality and functionality. 

Prototype Development Methods

When you reach the prototype development stage, you should already have a CAD design as close as possible to your final product. Prototypes still form a crucial part of the process to ensure the CAD design can be manufactured correctly before full-scale production. 

There are a few different methods for creating prototypes in manufacturing. These include:

• 3D and 2D model images: One option is to transform CAD drawings into 3D or 2D models, which are detailed images with layers that replicate your built product. This can save time and materials. You can also run simulations to test the performance of your prototype. 
• Computer numerical control (CNC) machining: CNC machining can handle complex designs and offers a fast turnaround for precision-made prototypes using automation for quality and speed. This machine can make larger quantities of items or one-offs, which is ideal for prototyping. 
• Working with a custom machining provider: Creating a functional prototype may be difficult without using more complex machines that you do not have on-site. This is where working with a partner with custom machining capabilities can help find the right machines and processes for your product.

Once you’ve produced a prototype, you’ll need to test it against your original specifications to see if it passes your parameters. You can also create a testing plan to analyze the fit, feel and function of your product while taking manufacturability into account. Record the results of the testing and use them to refine your CAD model. This helps you address any flaws in the prototype before committing to a full run.

From Prototypes to Full Runs

The next stage of the product development process is to scale up to a full run. You should prepare for this in a few ways, including:

• Ensure you can source enough materials for your needs.
• Review your design and manufacturing processes to make them as efficient as possible with some longer test runs.
• Outsource to a contract manufacturer to simplify your supply chain while meeting your production needs.

For your full production run, you should put together some key documents for your product. This includes your final CAD drawings, a bill of materials (BOM) and quality standards. A BOM for manufacturing can ensure the correct number of parts are manufactured and assembled according to your original specifications. Quality standards monitor for defects to prevent you from sending a faulty product to a customer. 

Develop Top-Quality Products From CAD to Manufacturing With PBZ

Taking a product from concept to a full production run requires precise planning and collaboration between stakeholders. Each stage offers opportunities to fine-tune your product, and the earlier you optimize your design, the more you can prevent costly errors and save time and money. Working with an experienced contract manufacturer can remove some of the burden and streamline your processes. 

At PBZ Manufacturing, we have provided resourceful manufacturing solutions for over 70 years. We can help you bring your products to life from design stages through to shipping, including all the stages of manufacturing.

As a one-stop-shop metal manufacturer, we simplify your supply chain and can shorten lead times and lower costs. For your product development needs, contact us today or call 717-721-5350.

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