DFMA
1. Explain why applying DFMA early in the design process has a larger impact
on total product cost than applying it later.
2. If two products perform the same function but one costs twice as much to
make, what design factors might explain the difference?
3. Imagine you are redesigning a product that has many small screws. What
alternative fastening methods could reduce assembly time and errors?
4. Explain why reducing part count is so important in product design. List the
three key questions used to test whether a part must remain separate in a
design.
5. Imagine you are redesigning the casing of a smartphone. Identify three
DFMA design rules you would apply and explain how each rule would
improve manufacturing efficiency or product quality.
6. Describe general design rules or principles of DFMA that help simplify
production and improve product quality.
(Hint: Consider ideas such as simplifying manufacturing steps, using
standard parts, and ensuring ease of assembly.)
7. Give two examples of everyday products that demonstrate good DFMA
design.
For each product, briefly explain:
1. Which DFMA rules are being applied (e.g., minimize part count,
modularity, standard parts).
2. How these rules help reduce cost, assembly time, or maintenance effort.
Classification of Manufacturing
1. Which method provides the best combination of forming complex shapes
efficiently and then achieving micron-level surface precision?
A. 5-axis CNC machining alone
B. Die casting followed by precision CNC machining
C. Water-jet machining
D. Chemical machining
Answer: B
2. Traditional machining differs from nontraditional machining mainly because:
A. Nontraditional processes always remove chips
B. Traditional processes rely on mechanical energy
C. Traditional processes generate no heat
D. Nontraditional processes cannot machine metals
Answer: B
3. Which nontraditional machining method is most suitable for producing deep,
precise cavities in very hard, heat-treated conductive materials?
A. Chemical milling
B. Water-jet machining
C. Electrical Discharge Machining (EDM)
D. Laser machining
Answer: C
4. For producing millions of high-precision metal smartwatch mid-frames, which
route is most appropriate?
A. 5-axis CNC machining only
B. Die casting + CNC finishing
C. Metal injection molding + CNC finishing
D. Water-jet cutting only
Answer: B
5. Which process produces no heat-affected zone (HAZ)?
A. Laser machining
B. Plasma machining
C. EDM
D. Water-jet machining
Answer: D
6. The main reason to select chemical machining for thin sheet components is:
A. High speed
B. No tool wear
C. No mechanical forces and burr-free etching
D. Best for thick materials
Answer: C
7. Which nontraditional process must be performed in a vacuum environment?
A. EDM
B. Laser machining
C. Electron-beam machining
D. Abrasive water-jet machining
Answer: C
8. Compare subtractive (machining), formative (casting/forging), and hybrid
manufacturing in terms of accuracy, cost, and typical use cases.
9. What factors must be considered when determining the appropriate
manufacturing process for a part?
10. Compare EDM, ECM, Laser Machining, and Water-Jet Machining in terms of
suitable materials, key advantages, and applications.
11. A high-precision ceramic component requires a ±5 µm tolerance. Analyze
which manufacturing methods should be used and explain the process route.
Additive Manufacturing
1. List the major advantages of additive manufacturing.
2. Write out the major types of additive manufacturing technologies.
3. Compare Selective Laser Sintering (SLS) and Selective Laser Melting (SLM) in
terms of processing principles, material behavior, and resulting part properties.
4. Among FDM, SLA, SLS, and Material Jetting, identify which technology is
most suitable for producing highly detailed prototypes and justify your choice.
5. Analyze the key consideration factors involved in DFMA and compare them
with the consideration factors used in DFAM.
6. Discuss the major stages in the additive manufacturing workflow from CAD
model to final prototype, and explain the key considerations at each stage.
7. Identify the major challenges associated with additive manufacturing and
describe the processes or strategies that can be used to reduce or mitigate these
challenges.
8. Describe one process-control strategy that can minimize common additive
manufacturing defects and explain why it is effective.