In this episode, we talk about Zeiss - one of the global leaders for high precision metrology equipment - leveraging additive manufacturing to streamline their production process from the design stage to assembly and how they’re able to do all this while satisfying their customers' ever specific needs effectively and efficiently.

Podcast: 3D Printing Saves Optical Sensors

<p>This article covers 10 essential tips for CNC machining design.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/lb5i00DHGG8?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h2 id="isPasted"><strong>1. Avoid excessively thin walls</strong></h2><p>Decreasing the wall thickness affects the stiffness of the material and reduces achievable accuracy as a result of inevitable vibrations during machining. The standard minimum wall thickness is 0.794 mm for metals and 1.5 mm for plastics. If you require thinner walls, you can use other suitable and cost-effective manufacturing processes like <a href="https://xometry.eu/en/sheet-metal/" target="_blank">sheet metal fabrication</a>.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002399942-wall-thickness-1440x584.png" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">The minimum wall thickness depends on the type of material</em></span></span></span></p><h2 id="isPasted"><strong>2. Avoid designing features that cannot be CNC machined</strong></h2><p>An example of a feature in CNC machined parts that CNC mills, lathes or drills cannot produce is &ldquo;curved holes&rdquo;. If you require this feature or others that can&rsquo;t be machined for your design, you can use electrical discharge machining (EDM) instead.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002415962-shapes-impossible-cnc-machined.png" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>3. Avoid excessive use of tight tolerances</strong></h2><p>If you don&rsquo;t specify tolerances in your design, the machine would simply use its standard tolerance. This helps save time and money. You should only specify tight tolerances when absolutely necessary. If you do specify tight tolerances, you should maintain consistency throughout your design. This helps reduce machining time.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002433283-homogeneous-tolerancing.png" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Avoid excessive use of tolerances</em></span></span></span></p><h2 id="isPasted"><strong>4. Avoid unnecessary aesthetic features</strong></h2><p>Some aesthetic features cannot be efficiently machined. As a designer, you should ask yourself: &ldquo;What CNC machining process would this feature require?&rdquo; or &ldquo;Is it a 5-axis or a 3-axis machining process?&rdquo;</p><p>You can improve your design by focusing on the accuracy of required features rather than aesthetics. It is best to use post-machining processes to change aesthetics.</p><h2><strong>5. Design cavities with accurate depth-to-width ratios</strong></h2><p>Cavities that are too deep can result in tool hanging, tool deflection, chip evacuation issues, and tool fracture. Cavity depths should not exceed 3-4 times their width. If larger depths are required, you should consider designing your part with a variable cavity depth. Cavity depths higher than six times their width are considered deep.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002455698-cavities-cnc.png" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>6. Add a radius when designing internal vertical edges</strong></h2><p>Most cutting tools are cylindrical and cannot machine sharp internal edges, meaning it is important to add a radius to internal edges in your design. To avoid unnecessary wear and tear of the tool, a good rule of thumb is to add a radius of 130% of the milling tool radius. If you need sharp internal corners, consider adding undercuts instead of reducing the edge radius.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002472729-internal-edges-cnc.png" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>7. Limit thread length</strong></h2><p>Unnecessarily long threads increase machining costs. The strength of the connection does not increase any when the thread length exceeds the size of the diameter by more than 1.5 times.</p><ul><li>Design threads should be no longer than 2 times the hole diameter&nbsp;</li><li>For blind holes, add an unthreaded length of at least half the diameter at the bottom of the hole</li></ul><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002491544-thread-length.png" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>8. Avoid extremely small features</strong></h2><p>Most CNC machines have a minimum tool diameter of 2.5 mm, meaning any feature smaller than 2.5 mm would be difficult to machine and would require special tools, which increases machining costs and time.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002508820-small-features.png" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>9. Design holes with standard sizes</strong></h2><p>Holes are machined quickly and accurately when standard drill bits are used. This means you won&rsquo;t need end mills or reamers to finish the hole size to a non-standard dimension.</p><p>Usually, increments of 0.1 mm are used for holes up to 10 mm in diameter, and increments of 0.5 mm are used for larger holes.</p><p>You should also limit the depth of holes to four times their diameter. It is possible to machine deeper holes (up to 10 times the diameter), but this will increase costs.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1694002526846-standard-hole-size.png" style="width: 766px;" class="fr-fic fr-dib"></p><h2 id="isPasted"><strong>10. Avoid unnecessary text and lettering</strong></h2><p>Any required text can be painted or laser engraved on the surface of the machined part during the finishing process. If machined text is required, adhere to the following rules:</p><ul><li>Choose engraving instead of embossing. This way, less material is removed.</li><li>Use 20-point Sans Serif fonts to help keep costs low. Also, many CNC machines are already programmed for these fonts</li></ul><h2><strong>CNC machining services at Xometry</strong></h2><p>At Xometry Europe, we offer <a href="https://xometry.eu/en/cnc-milling/" target="_blank">CNC milling</a> and <a href="https://xometry.eu/en/cnc-turning/" target="_blank">CNC turning online services</a>, as well as high-precision, fast, and quality CNC machined parts made of aluminium, stainless steel, steel, copper alloys, and many others. For any questions regarding CNC machining design, you can also refer to our <a href="https://xometry.eu/en/guide/design-guide-cnc-machining/" rel="sponsored nofollow" target="_blank">CNC machining design guide</a>.</p>

The design process for CNC machining requires precision and accuracy to produce quality designs. This is why there are recommended general CNC machining design rules that apply to the most common features of CNC machined parts.

Design Tips For CNC Machining

<p>Sheet metal fabrication is a well-established production process used in manufacturing sheet metal parts. It involves using techniques such as bending, punching, cutting, forming, etc., to fabricate sheet metal. After producing a sheet metal part, depending on the use and other factor, the sheet metal part can be subjected to a post-processing stage by the application of sheet metal finishes.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693473849454-sheet-metal-finishing-options.jpg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">The post-processing stage involves applying sheet metal finishes on the fabricated part. While it is not a requirement, it is an important step for many sheet metal metals. For example, aluminum sheet metal finishes are important for durability and anti-rust properties. There are many types of sheet metal finishes that you can apply in modern-day sheet metal fabrications. To make it easy, this article will elaborate on common and high-quality sheet metal finishing options you can use and how to select the right ones. Let us dive right in!</p><h2><strong>Sheet Metal Finish</strong><strong>ing</strong><strong>&nbsp;Options</strong><strong>&nbsp;</strong><strong>You Can Use</strong></h2><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693473864286-sheet-metal-finshing-option-you-can-use-1-1024x683.jpeg" style="width: 766px;" class="fr-fic fr-dib"></p><p id="isPasted">This section will introduce the different sheet metal finishing processes you can add to your <a href="https://www.rapiddirect.com/blog/six-helpful-design-tips-for-sheet-metal-fabrication/" target="_blank" rel="noreferrer noopener">sheet metal design</a> plan. This will include a short mechanism of action, uses, advantages, and disadvantages.</p><h3><strong>1. Bead Blasting</strong><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693473876624-bead-blasting.jpg" style="width: 766px;" class="fr-fic fr-dib"></strong></h3><p id="isPasted">Bead blasting is a finishing process that involves shooting thousands of tiny abrasive particles (such as glass or sand) at the sheet metal part surface using compressed air. The sustained impact of these tiny beads on the metal&rsquo;s surface creates smooth sheet metal surface finishes with matte textures.</p><p>Bead blasting is a fairly standard sheet metal finishing process. However, it is also ideal for cleaning or removing paint from finished parts. The visual quality of bead-blasted metal parts makes the post process a popular option for visual applications that require a matte quality. Consequently, it is one of the common aluminum sheet metal finishes you can use for parts that require high visual quality. Bead blasting can also be followed by other finishing processes if needed, and it is ideal for parts that require cosmetic properties</p><h4><strong>Advantages</strong></h4><ul><li>Bead blasting is a safe method that is compatible with aluminium, brass, stainless steel, steel.</li><li>It is long-lasting when compared to other sheet metal finishes</li><li>The process is environmentally friendly.</li><li>It is ideal for treating sensitive surfaces.</li><li>The sheet metal finishes (sand or glass) are majorly non-reactive.</li></ul><h4><strong>Disadvantages</strong></h4><ul><li>It is not a fast sheet metal finishing solution.</li><li>Using silica as sheet metal finishes can lead to <a href="https://www.silica-safe.org/know-the-hazard/why-is-silica-hazardous" target="_blank" rel="noreferrer noopener">siliceous hazard</a>s indicated as lung disease and cancer.</li><li>It is not economic for small projects</li><li>There is a need for high precaution measures by the operator.</li></ul><h3><strong>2. Anodizing</strong><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693473895346-anodized.jpg" style="width: 766px;" class="fr-fic fr-dib"></strong></h3><p id="isPasted"><a href="https://www.rapiddirect.com/blog/your-basic-guide-to-anodizing-aluminum/" target="_blank" rel="noreferrer noopener">Anodizing</a> is another sheet metal finishing solution used for aluminum and titanium sheet metal parts. It is a technique that uses an electrochemical process to create a corrosion-resistant layer on the surface of the sheet metal part.</p><p>The process involves submerging a sheet metal part into an acid electrolyte bath and exposing it to an electric current. The combination of these elements results in the conversion of the sheet metal part&rsquo;s surface into an anodic oxide layer that is fully integrated into the part surface.</p><p>The process is only compatible with aluminum and titanium metals and is available in three variations: Type I, Type II, and Type III.</p><ul><li>Type I anodization involves using chromic acid to create thin layer sheet metal finishes on the sheet metal surface.</li><li>Type II anodization results in a strong corrosion-resistant layer by using sulfuric acid instead of chromic acid.</li><li>Hardcoat anodization/Type III, results in thicker sheet metal finishes that are corrosion resistant and wear-resistant.</li></ul><p>Anodization can also impart a variety of surface finish colors. It is a common finishing process in producing mechanical parts, aircraft and automotive components, precision instruments and more.</p><h4><strong>Advantages</strong></h4><ul><li>It has excellent corrosion and abrasion resistance</li><li>There is no risk of adhesion failure, fading, and chalking.</li><li>Anodization produces perfect and irremovable sheet metal finishes</li><li>The end product is UV stable</li><li>It offers a wide range of sheet metal finishes.</li></ul><h4><strong>Disadvantages</strong></h4><ul><li>It has a lower range of compatible materials.</li><li>Titanium and aluminum sheet metal finishes have lower thermal conductivity.</li><li>It is not compatible with stainless steel</li><li>It is hard to replicate consistency when dealing with different sheet metal parts</li></ul><h3><strong>3. Powder Coating</strong><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693473916628-powder-coating-1024x663.jpg" style="width: 766px;" class="fr-fic fr-dib"></strong></h3><p id="isPasted">Powder coating is an aesthetic finishing process that consists of spraying powdered paint onto the surface of a material. In sheet metal fabrication, the sheet metal is then baked to paint bonds to its surface. This creates a strong layer that is corrosion resistant and wear-resistant. Therefore, powder coating is superior to more conventional painting methods because it creates a strong layer outside the component.</p><p>Powder coating is available in many colors (including any RAL code or Pantone hues) to meet the client&rsquo;s aesthetic and brand requirements. It is also available in various sheet metal finishes, such as glossy, semi-glossy, flat, metallic and textured. Prices for powder coating are variable depending on the color, finish and part geometry.</p><h4><strong>Advantages</strong></h4><ul><li>It has excellent corrosion and abrasion resistance</li><li>There is no risk of adhesion failure, fading, and chalking.</li><li>The sheet metal finishes implanted is long-lasting and economical</li><li>The end-product is non-toxic and less flammable.</li><li>It offers a wide range of sheet metal finishes available for virtually any type of sheet metal</li></ul><h4><strong>Disadvantages</strong></h4><ul><li>You cannot mix powders to achieve different colors.</li><li>It can be a little costly.</li></ul><h3><strong>4. Electroplating</strong><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1693473934351-electroplating.jpg" style="width: 766px;" class="fr-fic fr-dib"></strong></h3><p id="isPasted">This is another popular sheet metal finishing process in which fine layers of another type of metal (sacrificial metal) are deposited on the sheet metal part&rsquo;s surface. Electroplating occurs by placing the sacrificial metal on the anode position and the sheet metal part on the cathode position. Both metals are placed inside an electrolyte similar to the anodic material. The two types of metal are then chemically bonded through electric conduction.</p><p>There are several options for the electroplating material, each of which provides a different combination of properties. At RapidDirect, we can electroplate sheet metal parts using tin, nickel and electroless nickel. It is important to note that if electroplating is used, then tolerances of the original part should account for the final plating&rsquo;s thickness.</p><p>Electroplating can increase conductivity (depending on the sacrificial metal) and increase a part&rsquo;s resistance to radiation and is thus commonly used to produce radiation shields.</p><h4><strong>Advantages</strong></h4><ul><li>It has excellent corrosion and abrasion resistance</li><li>There is an improvement in conductivity.</li><li>Electroplating reduces friction.</li><li>It is compatible with many types of sheet metals</li></ul><h4><strong>Disadvantages</strong></h4><ul><li>It can be a little costly.</li></ul><p>As one of China&rsquo;s premier online rapid prototyping services, RapidDirect offers a broad range of sheet metal finishing solutions to its customers around the globe. We understand that every rapid prototyping and production job is different, and we work with our customers to ensure that their parts meet every requirement.</p><p>In combination with our extensive sheet metal fabrication capabilities, RapidDirect professional finishing solutions ensure that you always have the best quality part in hand at the end of the day, whether it is a prototype or end-use component.</p><p>In addition to sheet metal fabrication, we also offer CNC Machining, Injection Molding and 3D Printing production services. Find out more about CNC Machining finishing solutions and Injection Molding finishing solutions. And stay tuned for a blog post about 3D Printing finishing solutions.</p><h2 id="isPasted"><strong>How to Select the Right Sheet Metal Finishing Process</strong></h2><p>Having basic knowledge about sheet metal finishes to apply is not the only thing. You must also know how to select the right sheet metal finishing solution. Below are a few factors that will help you in selecting the right sheet metal finishing process:</p><h3><strong>1. The Type of Material</strong></h3><p>The type of material you are working with determines the sheet metal finishing process you can use. Some sheet metal finishing processes are only compatible with some materials. For example, anodizing is only compatible with aluminum and titanium.</p><p>Also, different types of material have different hardness properties. Using an abrasive finishing solution such as bead blasting with soft sheet metals can damage the part.</p><h3><strong>2.&nbsp;Coating Thickness</strong></h3><p>Coating thickness is another factor that determines the sheet metal surface finishes that you can use. When comparing the different finishing solutions highlighted above, you will notice a trend. Below is a list of coating thicknesses for some of the above finishing solutions:</p><ul><li>Powder coating produces thickness ranging from 35 &micro;m to 200 &micro;m.</li><li>Anodization produces thickness ranging from 0.5 &micro;m to 150&micro;m depending on the type.</li><li>Electroplating produces thickness ranging from 5 &micro;m to 25 &micro;m.</li></ul><h3><strong>3.&nbsp;Uses</strong></h3><p>Sheet metal finishes are mostly applied due to aesthetics or functional reasons. Each finishing solution discussed above is suitable for aesthetic function, albeit to a different degree. Also, the finishing solutions are suitable for functional use, also to a different degree. For example, it is only necessary to apply stainless steel sheet finishes if you think more of aesthetic reasons. However, aluminum sheet metal finishes are common for both aesthetics and functional reason.</p><h3><strong>4.&nbsp;Turnaround Time</strong></h3><p>The production speed is also another important factor you should consider when choosing a finishing solution. If you have a short turnaround time, you should choose a fast sheet metal finishing solution and vice versa. However, combine this factor with quality as quality is sometimes synonymous with higher production time.</p><h3><strong>5.&nbsp;Cost</strong></h3><p>Finally, the most important factor determines what type of sheet metal finishes you can use. You should explore all possible options in terms of price before choosing the right one. Some finishing solution, e.g.,&nbsp;<a href="https://www.rapiddirect.com/blog/factors-affecting-the-cost-to-anodize-aluminum/" target="_blank" rel="noreferrer noopener">anodizing</a> is very costly. You should know how to combine cost and quality to produce something unique.</p><h2><strong>Conclusion</strong></h2><p>Sheet metal finishes are an important part of sheet metal fabrication. They are important for aesthetics or functional use needed by many manufacturing industries. &nbsp;There are many&nbsp;<a href="https://www.rapiddirect.com/blog/metal-surface-finishing/" target="_blank" rel="noreferrer noopener">sheet metal finishing processes</a> you can use. However, this article talked about high-quality finishing processes you can employ in your projects. The article showed their principle, advantages, and disadvantages to further ease the selection process.</p>

Sheet metal fabrication is a well-established production process used in manufacturing sheet metal parts. It involves using techniques such as bending, punching, cutting, forming, etc., to fabricate sheet metal. After producing a sheet metal part, depending on the use and other factor, the sheet metal part can be subjected to a post-processing stage by the application of sheet metal finishes.

The Ultimate Guide to Sheet Metal Surface Finishes Solutions

Beware the fakes.  Don't leave your production open to failure from counterfeit exposure. 

Cody Endlich, MacroFab's head of strategic sourcing, discusses counterfeit PCBA parts and their impact on electronic builds, and how MacroFab has managed a zero percent failure rate for nonconformity or counterfeit parts.

The Risks of Counterfeit PCBA Parts in Electronics Manufacturing

<p id="isPasted"><a href="https://xometry.eu/en/die-casting-general-overview-process-materials-applications/" target="_blank">Die casting is a process</a> where molten metal is injected into a mould under high pressure. It is used to produce parts with complex shapes that would be difficult or impossible to machine using traditional methods. Hence the importance of having a good design for your die casting projects.</p><p>Designing perfect die cast parts is about taking into account the design of the die, the type of metal being used, the production process, and the application of the final product. In other words, it&rsquo;s about ensuring that every element comes together to create a functional, durable, and aesthetically pleasing piece.</p><p>In order to get the most out of die casting, designers need to follow some basic tips.</p><h2><strong>Major considerations for die casting design</strong></h2><p>While designing a perfect die cast may seem like a daunting task, it is ultimately rewarding when you see your vision come to life in an appealing and functional final product. Here are some of the things you need to keep in mind during the design process:</p><ul><li>The die casting process can be used with a variety of metals, including aluminium, and zinc. Each metal has its own unique properties such as fluidity and solidification, which need to be taken into account during the design process</li><li>The die must be able to withstand the high pressures involved in the process and must be accurately machined to ensure a precise final product</li><li>The production process needs to be taken into account when designing die castings. For example, the design may need to accommodate the use of cores or inserts</li><li>The part should eject easily from the die without damaging the surface or leaving any flash</li><li>The part function and intended application must be prioritized when designing die castings. For example, a die casting used in a high-stress environment will need to be designed differently than one that is purely aesthetic</li></ul><h2><strong>Top design tips for die casting &ndash; Important variables</strong></h2><p>There are a few key variables that you need to take into account when designing your die casting. These include:</p><h3><strong>1. Fillets and radii</strong></h3><p>In die casting, one of the most important design tips is the fillets and radii. These features help to create smooth transitions between surfaces and prevent stress concentrations. As a result, they play a vital role in ensuring the strength, aesthetics, and durability of the final product.&nbsp;</p><p>The size and shape of the fillets and radii will depend on the specific application, but they should not be less than 1 mm.</p><p>Inappropriate fillets and radii can affect the strength of a component by changing its cross-sectional area. So here are some design tips related to fillets and radii:</p><ul><li>Avoid sharp corners as they can create stress concentrations</li><li>Use a larger radius for highly loaded areas</li><li>Pay attention to the radius at the junction of two surfaces as it can have a big effect on the strength of the joint</li><li>Use constant fillets and radii throughout the design to maintain the strength and smoothness of the component</li><li>Add draft angles to the surfaces aligned with the mould opening direction. It ensures that the component can be removed from the mould without damaging the surface. It typically ranges from 1 to 3 degrees, but it can be larger for more complex shapes</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872386362-die-cast-fillet-radius-768x512.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Examples of fillets and radii</em></span></span></span></p><h3 id="isPasted"><strong>2. Wall thickness</strong></h3><p>The wall thickness should be designed keeping in mind the desired strength, stiffness, and weight of the final product. It affects everything from the amount of time it takes to cool the cast to the amount of pressure that can be exerted on the mould.&nbsp;</p><p>The ideal wall thickness for a particular application depends on a number of factors, including the size and shape of the part, the materials used, and the production process.</p><p>Some of the minimum wall thicknesses for large and small castings are as below:</p><ul><li>Aluminium: 1.016 &ndash; 2.032 mm</li><li>Zinc: 0.381 &ndash; 0.889 mm</li><li>Magnesium: 1.016 &ndash; 2.54 mm</li></ul><h3><strong>3. Ribs and external corners</strong></h3><p>Ribs are used to reinforce the wall of a component and to increase its stiffness. They also help to distribute the load evenly and prevent warping. External corners are often used to create sharp transitions between surfaces. Both of these features need to be taken into account when designing die castings.</p><p>The thickness of the ribs and external corners will depend on the specific application. For example, thicker ribs may be needed for a component that is going to be under a lot of stress.</p><p>Some other important design tips related to ribs and external corners are:</p><ul><li>Ribs should be added to the thinnest wall first to prevent the component from becoming too thin</li><li>The spacing between the ribs should be kept uniform and the external corners should be avoided if possible, to prevent stress concentrations</li><li>If external corners are necessary, the radius should be as large as possible to reduce the stress</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872413135-die_cast_ribs-768x509.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted"><em>Part with ribs and metal saving features</em></em></span></span></span></p><h3 id="isPasted"><strong>4. Windows and holes</strong></h3><p>Windows and holes are often used in die castings to allow for the passage of fluids or to create a connection point between two parts. They need to be taken into account when designing the casting to ensure that they do not affect the strength or integrity of the final product.&nbsp;</p><p>Windows are typically located on the top or side of the mould and are generally rectangular in shape. Holes, on the other hand, can be located anywhere on the mould and come in a variety of shapes (e.g. round, square, etc.).&nbsp;</p><p>When designing windows and holes, it is important to keep the following in mind:</p><ul><li>The edge of the holes and windows should be rounded/filleted</li><li>Holes and windows should be located away from sharp corners and edges</li><li>Higher draft angles may be needed for windows and holes that are located on the side of the mould</li><li>In some cases, it may be necessary to post-machine the holes and windows, but it will increase the production time and the cost</li></ul><h3><strong>5. Post machine features</strong></h3><p>Some features, such as threads or undercuts, can only be created after the casting has been made. This is typically done through a process called post-machining. Post-machining is an additional step in the manufacturing process and will increase the lead time and die cast part cost. It is important to keep this in mind when designing die castings.</p><p>If post-machining is necessary, the following tips should be taken into account:</p><ul><li>The location of the feature should be considered to minimize the amount of material that needs to be removed</li><li>The feature should be designed so that it can be easily and accurately machined</li><li>The tolerances of the feature should be realistic and achievable</li><li>In order to maintain the cost, try to add minimum post machine features to die casting parts</li><li>Post machined features can also be added during the design phase by using cores. Cores are internal features that are created in the mould to create holes, pockets, or other features in the final casting</li></ul><h3><strong>6. Parting lines</strong></h3><p>The parting line is the line where the two halves of the mould meet. It is typically located on the side or top of the component. The parting line needs to be taken into account when designing die castings because it will cause a visible seam on the final product.</p><p>There are a few things to keep in mind when designing the parting line:</p><ul><li>The parting line should be located in a place where it will be the least visible</li><li>Parting lines that are too thin can cause the part to shatter when it is ejected whereas; too thick parting lines can result in uneven surfaces and imperfections in the finished product</li><li>It often exhibits flash which is an extra material that forms along the parting line. The flash can be removed in the post-processing stage</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872438458-die-cast-parting-line-768x406.jpg" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner"><em id="isPasted">Example of parting line and flash in die casting</em></span></span></span></p><h3 id="isPasted"><strong>7. Surface finishing grades for die casting</strong></h3><p>After completing the casting process, the surface of the die casting will need to be finished. The type of finish will depend on the application of the final product. The product comes out from the die casting process with an as-cast surface finish.&nbsp;</p><p>The surface finishing is classified into different grades, the most common being:</p><ul><li>Grade-1 (Utility Grade)</li><li>Grade-2 (Functional Grade)&nbsp;</li><li>Grade-3 (Commercial Grade)</li><li>Grade-4 (Consumer Grade)</li><li>Grade-5 (Superior Grade)</li></ul><figure><table><tbody><tr><td><br></td><td><strong>Class &ndash; 1</strong></td><td><strong>Class &ndash; 2</strong></td><td><strong>Class &ndash; 3</strong></td><td><strong>Class &ndash; 4</strong></td><td><strong>Class &ndash; 5</strong></td></tr><tr><td><strong>Grade names</strong></td><td>Utility grade</td><td>Functional grade</td><td>Commercial grade</td><td>Consumer grade</td><td>Superior grade</td></tr><tr><td><strong>As-Cast Finish</strong></td><td>No cosmetic required</td><td>Spot polishing and painting</td><td>Zinc plating, electrostatic painting, and custom finishing</td><td>No-objectionable surface defect</td><td>Finish applied to the specific area in micro-inches</td></tr><tr><td><strong>Final Products</strong></td><td>Cast product with protective coating</td><td>Cast product with decorative coating</td><td>Structural parts for high-stress applications</td><td>Decorative parts</td><td>Gasket sections and O-ring seats</td></tr><tr><td><strong>Finishing Quality</strong></td><td><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455780-1692872455780.png" class="fr-fic fr-dii" style="width: 20px;"></td><td><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455876-1692872455876.png" class="fr-fic fr-dii" style="width: 17px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455968-1692872455968.png" class="fr-fic fr-dii" style="width: 17px;"></td><td><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455950-1692872455950.png" class="fr-fic fr-dii" style="width: 17px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455913-1692872455913.png" class="fr-fic fr-dii" style="width: 16px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872456009-1692872456009.png" class="fr-fic fr-dii" style="width: 16px;"></td><td><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455987-1692872455987.png" class="fr-fic fr-dii" style="width: 18px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872456049-1692872456049.png" class="fr-fic fr-dii" style="width: 17px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455820-1692872455820.png" class="fr-fic fr-dii" style="width: 18px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455841-1692872455840.png" class="fr-fic fr-dii" style="width: 16px;"></td><td><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872456025-1692872456025.png" class="fr-fic fr-dii" style="width: 17px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455932-1692872455932.png" class="fr-fic fr-dii" style="width: 16px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455895-1692872455895.png" class="fr-fic fr-dii" style="width: 16px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455858-1692872455858.png" class="fr-fic fr-dii" style="width: 17px;"><img draggable="false" alt="⭐" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692872455801-1692872455801.png" class="fr-fic fr-dii" style="width: 18px;"></td></tr></tbody></table></figure><p>You can choose the one depending on your requirements and budget. We suggest you to choose the minimum required grade if you want to maintain the part cost.</p>

In this article, we'll discuss the design tips and guidelines that will help you get the best results from your die casting projects.

Design Tips for Die Casting

<p data-pm-slice="1 1 []" id="isPasted"><a href="https://fractory.com/heat-treatment-methods/" target="_blank">Heat treatment processes</a> involve precise heating and cooling procedures to change the physical and mechanical properties of metals. Generally, to alter undesirable properties and strengthen desirable ones.</p><p>One such heat treatment process is annealing,&nbsp;<span data-color="rgb(247, 247, 248)">which allows us to modify the&nbsp;<a href="https://fractory.com/mechanical-properties-of-materials/" target="_blank">mechanical characteristics</a> of certain metals and alloys to better match their intended use.</span></p><p>Let&rsquo;s begin.</p><h2 id="isPasted">What Is Annealing?</h2><p>The annealing process uses heat to reduce the hardness and increase the ductility and toughness of various steels, cast iron, and alloys. It involves heating the workpiece beyond its recrystallisation temperature. Doing so encourages new grain formation and allows the existing grains to reorient.</p><p>Grain rearrangement and formation relieve the internal stresses of the metal and give the crystal structure a more refined flow. This is a beneficial property for most use cases.</p><p>Because of the wide variety of steel and metal alloys, there are many specialised types of annealing processes available. The most common ones are full or complete annealing and process annealing (aka intermediate annealing or recrystallisation annealing).</p><p>Although <a href="https://fractory.com/normalising-explained/" target="_blank">normalising</a> is often considered a separate heat treatment process, it is actually a type of annealing process where the metals are cooled at room temperature instead of letting them cool at a controlled rate inside a furnace.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1692700567172-different-types-of-annealing.jpg.jfif" style="width: 766px;" class="fr-fic fr-dib"></p><h3 id="isPasted">When Is Annealing Used?</h3><p>Annealing creates softer steel than&nbsp;<a href="https://fractory.com/tempering-explained/" target="_blank">tempering</a> and is thus mostly used on products that do not need to endure substantial stresses. But there are many different instances when annealing is used on metal parts:</p><ol><li><p>Reversal of work hardening</p></li><li><p>Softening of weld solidification</p></li><li><p>Development of electrical conductivity</p></li><li><p>Removal of residual stresses</p></li></ol><h4>Reversal of work hardening</h4><p>Annealing is usually done after a product undergoes mechanical operations that lead to hard and brittle metals.&nbsp;<a href="https://fractory.com/sheet-metal-bending/" target="_blank">Bending</a>, forming,&nbsp;<a href="https://fractory.com/hot-rolled-steel-cold-rolled-steel/" target="_blank">rolling</a>, grinding, and drawing are all apt examples of such operations. For instance, when a metal wire is drawn to reduce its size, it develops internal stresses and hardens.</p><p>The resultant hardness in worked metals makes further processing difficult and risky as the metals may crack. But further processes are an operational requirement. Thus, to return a metal to its pre-work state and make it more acceptable to subsequent operations, we carry out process annealing.</p><p>Annealing increases the ductility of the metal and reduces its hardness. This makes the workpiece more formable and machinable. Annealed metals can thus undergo&nbsp;<a href="https://fractory.com/common-metal-fabrication-processes/" target="_blank">further operations</a>.</p><p>The annealing process is especially useful when manufacturing complex parts. As we need to carry out many operations, the annealing process helps us return the part closer to its pre-work state after every operation.</p><h4>Softening of weld solidification</h4><p><a href="https://fractory.com/types-of-welding-processes/" target="_blank">High-temperature welding processes</a> can cause the formation of&nbsp;<a href="https://fractory.com/heat-affected-zone-causes-effects-reduction/" target="_blank">heat-affected zones (HAZ)</a>. These zones are characterised by having high hardness and brittleness. In such cases, annealing returns the HAZ&rsquo;s&nbsp;properties closer to its original mechanical properties.</p><h4>Development of electrical conductivity</h4><p>Annealing can also affect the electrical properties of a metal. Thus, it is also utilised to improve the electrical conductivity of certain metals.</p><h4>Removal of residual stresses</h4><p>Besides affecting the formability and machinability of a material, cold working also causes internal stresses to the material. Even when there are no further operations to be performed, it is a good practice to relieve the internal stresses that crop up after various mechanical operations.</p><p>Not addressing them can lead to cracking, material fracture, distortion and other mechanical issues in the future.</p><p>Annealing enables us to relieve residual stresses and regain uniform properties in the material. This increases the service life and operational capabilities of the selected materials.</p><h2 id="isPasted">The Annealing Process</h2><p>The annealing process can be divided into three distinct stages.</p><ol><li><p>Recovery stage</p></li><li><p>Recrystallisation stage</p></li><li><p>Grain growth stage</p></li></ol><h3><strong>Recovery Stage</strong></h3><p>In the recovery stage, we heat the metal to a predetermined temperature below the melting point. A heating device such as a furnace or oven is used for heating in a controlled and consistent environment.</p><p>The furnace heat reduces the number of dislocations as the atoms start migrating in the crystal lattice. This returns ductility and reduces the&nbsp;<a href="https://fractory.com/material-hardness/" target="_blank">hardness of the material</a>. The migration processes also eliminate internal stresses and thus this stage is known as the recovery stage.</p><h3><strong>Recrystallisation Stage</strong></h3><p>Once the desired temperature is achieved, we heat the metal further up to its recrystallisation temperature. The recrystallisation temperature also lies below the metal&rsquo;s melting point. This is the same temperature that is targeted when normalising metal products.</p><p>Upon achieving this temperature, we hold the metal at it for a set amount of time. The duration depends on the desired properties and metal grade.</p><p>In this stage, the crystal structure begins reorganising itself and the formation of new grain structures begins. This reverses the effects of hardening and helps return the material properties to their pre-work levels.</p><h3><strong>Grain Growth Stage</strong></h3><p>The grain growth stage increases the size of the newly formed as well as the former grains once the cooling begins. Factors such as the cooling rate, atmosphere and material grade determine the phase composition and the crystal grain size and growth.</p><p><a href="https://fractory.com/ferrous-metals-non-ferrous-metals-with-examples/" target="_blank">Steel and other ferrous metals</a> are typically cooled to room temperature in the presence of still air. On the other hand, metals such as copper and brass may be either cooled slowly in air or quickly drenched in water. Compared to normalising, the cooling rate in annealing is slower.</p><p>Sometimes further operations may be required after annealing to attain the desired mechanical and chemical properties in the material.</p><h2>The Benefits of Annealing</h2><p>The annealing process provides the following benefits.</p><ol><li><p>Increased ductility</p></li><li><p>Increased toughness</p></li><li><p>Increased machinability and formability</p></li><li><p>Reduced hardness to match acceptable levels</p></li><li><p>Reduced or completely eliminated internal stresses</p></li><li><p>Improved homogeneity</p></li><li><p>Improved appearance</p></li><li><p>Better chemical and&nbsp;<a href="https://fractory.com/mechanical-corrosive-adhesive-material-wear/" target="_blank">wear resistance</a></p></li><li><p>Improved&nbsp;<a href="https://fractory.com/magnetic-metals-non-magnetic-metals-with-examples/" target="_blank">magnetic properties</a> and electrical conductivity</p></li><li><p>Reduced shrinkage</p></li></ol><h2>Conclusion</h2><p>Annealing is an important heat treatment process step in manufacturing complex parts as well as those that require multiple operations to reach their final form.</p><p>But annealing requires careful planning and execution. With the awareness of the correct material composition and&nbsp;<a href="https://fractory.com/iron-carbon-phase-diagram/" target="_blank">phase diagram</a>, annealing can help us soften many different types of metals. It is mostly performed on carbon steel and cast iron but also on other materials such as copper, aluminium and brass for its many benefits.</p>

Heat treatment processes involve precise heating and cooling procedures to change the physical and mechanical properties of metals. Generally, to alter undesirable properties and strengthen desirable ones.

One such heat treatment process is annealing, which allows us to modify the mechanical characteristics of certain metals and alloys to better match their intended use.

Annealing Explained - Definition, Process and Benefits

<section id="isPasted"><p>Designing electronic products requires a high degree of efficiency but must also meet the needs of an ever-more demanding target audience. This means that innovation and practicality are constantly competing. As a result, firms hoping to <a href="https://www.macrofab.com/webinars/ways-to-speed-time-to-market/" target="_blank">deliver a successful electronics product to market</a> are continually seeking out new, cutting-edge solutions and faster ways to design.</p><p>When designing Printed Circuit Board Assemblies (PCBAs), engineers must strike a balance between this efficiency and competitiveness. However, the path to successful PCBA product development has its challenges. Companies, often navigating a labyrinth of obstacles requiring swift and astute decision-making, must identify and understand the primary impediments to PCBA product development.</p><p>The following are the five primary obstacles to effective PCBA product development and how to circumvent them.</p><h2>Barrier #1 - Ineffective Teamwork</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605811159-1691605811159.png" alt="Ineffective teamwork barrier" class="fr-fic fr-dii"><p>For PCBA projects to be successful, it is important to have a strong team at the company level. Communicating and cooperating effectively across departments is essential. When these are lacking, the consequences can be significant, leading to wasted time and ongoing disputes that hinder the progress of a PCBA product launch.</p><p>One effective strategy for promoting teamwork is to use early testing. Early testing can clarify expectations and identify potential issues, fostering open and ongoing communication at the outset while establishing baseline standards that must be met.</p><p>Moreover, this powerful tool saves time and money in PCBA projects when implemented correctly. Specifically, teams that utilize early testing can achieve a 25 percent reduction in development time and a 30 percent decrease in rework.</p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605811647-1691605811647.png" alt="Open communication zoom meeting" class="fr-fic fr-dii"><p>Open communication is the cornerstone of a collaborative and productive team environment, particularly when it comes to the success of PCBA projects. To foster open communication within the team, consider implementing the following measures:</p><ul><li>Establish Cross-Functional Meetings: Regular cross-functional meetings with a clear agenda and prepared documents help align goals, ensure productivity, and keep everyone informed on critical points under development.</li><li>Use Collaboration Tools: Facilitate real-time communication with collaboration tools and file-sharing features to ensure all team members have access to resources and up-to-date documentation.</li><li>Cultivate a Culture of Transparency: Create a culture of openness by encouraging team members to voice their concerns and ideas while promoting active listening and open dialogue.</li></ul><p>By implementing these measures, teams can work together seamlessly, minimize inefficiencies, and achieve success in their PCBA projects. In addition, open communication enables teams to navigate challenges effectively and fosters a positive and inclusive team environment.</p><h2>Barrier #2 - The Costs of Delayed Testing</h2><p>Undertaking testing too late in the process can lead to a high-cost burden and numerous complications. The discovery of errors near the end of a project may require substantial modifications that might have been more easily resolved at an earlier stage.</p><p>This scenario can become even more challenging if skilled members of the team have already moved on to other projects or&ndash;worse&ndash;left the organization. Replacing such professionals can cost more than twice their annual salary, representing a considerable financial impact. To avoid such scenarios, taking proactive measures is crucial.</p><p>To enhance and streamline the testing process, consider these approaches:</p><a href="https://www.macrofab.com/blog/barriers-efficient-pcba-product-development/#" title="click to enlarge" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605811732-1691605811732.png" alt="Adopt shift left testing screenshot" class="fr-fic fr-dii"></a><ul><li>Adopt a &ldquo;shift-left&rdquo; testing approach: This promotes early design-phase testing activities as opposed to waiting until later stages. By integrating testing into initial design processes, teams can identify and address issues promptly, leading to improved quality and reduced overall costs.</li><li>Leverage simulation software: Simulation software can validate design performance before physical prototyping, and can provide invaluable feedback that will help your team detect potential flaws or design weaknesses as quickly as possible.</li><li>Conduct iterative testing: Cyclical and repetitive testing minimizes the chance of encountering significant problems toward the end of a project.</li></ul><a href="https://www.macrofab.com/blog/barriers-efficient-pcba-product-development/#" title="click to enlarge" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605812271-1691605812271.png" alt="Cost turnover graph" class="fr-fic fr-dii"></a><h2>Barrier #3 - Employee Churn:</h2><p>High employee turnover can significantly disrupt the PCBA product development process, leading to costly delays and declining project quality. The loss of experienced team members can create knowledge gaps, hinder collaboration, and increase training costs for new employees.</p><p>Churn can also be extremely costly. While replacing an unskilled worker may cost up to 20 percent of their annual salary, <a href="https://www.americanprogress.org/article/there-are-significant-business-costs-to-replacing-employees/" target="_blank">replacement costs can skyrocket to as much as 213%</a> for highly skilled positions.</p><p>Data points illustrating the impact of employee churn on project timelines and quality include:</p><ul><li>Increased time and resources spent onboarding and training new employees</li><li>Loss of institutional knowledge and expertise, leading to potential errors and inefficiencies</li><li>Lower team morale and productivity due to constant team restructuring</li></ul><p>To reduce employee churn and promote retention, consider implementing the following strategies. Provide competitive compensation and benefits as a first step. This involves not only offering competitive salaries but also a robust benefits package and clear pathways for professional development.</p><p>Secondly, cultivate a positive work environment. Keeping employees satisfied and motivated requires a supportive and inclusive workplace culture that promotes collaboration, recognition, and a healthy work-life balance.</p><p>Finally, prioritize the provision of growth opportunities. This can be achieved by encouraging employee development through continuous training, mentorship programs, and advancement opportunities.</p><a href="https://www.macrofab.com/blog/barriers-efficient-pcba-product-development/#" title="click to enlarge" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605812157-1691605812157.png" alt="Categories reasons for leaving retention" class="fr-fic fr-dii"></a><p>The Work Institute&rsquo;s 2020 Retention Report found that 76 percent of employee turnover is preventable through clearer communication, more opportunities for professional growth, or other management strategies. By addressing these issues, companies can reduce employee churn and thus improve the efficiency and quality of their PCBA product development projects. As companies in the industry struggle to retain knowledgeable employees, this becomes increasingly important.</p><h2>Barrier #4 - The Risks of Unallocated Duties</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605812098-1691605812098.png" alt="Risk unallocated duties" class="fr-fic fr-dii"><p>In the PCBA product development process, unclear roles and responsibilities can create a maze of confusion and delays. When task and milestone ownership is not properly designated, team members can operate in a state of uncertainty. This can result in inefficiencies and a lack of accountability, leading to critical tasks being overlooked. In extreme cases, this can cause missed deadlines and suboptimal project outcomes.</p><p>For instance, without a clear owner for the <a href="https://www.macrofab.com/blog/five-biggest-design-mistakes-for-pcbas/" target="_blank">product design review process</a>, teams may overlook critical considerations or make uninformed decisions, impacting the project&rsquo;s quality and deliverability. Conversely, when responsibilities are clearly defined, team members can focus on their areas of expertise, leading to more effective collaboration and timely project completion.</p><p>To overcome this barrier, implement the following strategies that assign responsibility, establish clear communication, and ensure accountability:</p><ul><li>Define Clear Roles at the Project&rsquo;s Outset: Develop a detailed project charter that outlines each team member&rsquo;s roles, responsibilities, and authority. The charter should include expectations regarding communication, collaboration, and decision-making to promote transparency and accountability.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605811970-1691605811970.png" alt="Leverage raci matrix project activities" class="fr-fic fr-dii"><ul><li>Leverage RACI Matrix for Project Activities: TheRACI (Responsible, Accountable, Consulted, Informed)matrix is an effective tool to assign ownership for each activity or deliverable in the project. By assigning an owner to every task and aligning stakeholders on their roles, the matrix can help clarify responsibilities.</li><li>Implement Regular Status Updates: Digital collaboration platforms can be utilized to allow team members to provide progress updates and address challenges. Asynchronous communication should be fostered to promote knowledge-sharing and collaborative problem-solving. Encouraging open communication is a critical first step.</li></ul><p>By adopting these strategies, teams can establish clarity in roles, enhance collaboration, and ensure accountability in their PCBA product development projects, leading to smoother execution and a higher likelihood of success.</p><h2>Barrier #5 - Ignoring the End Goal</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605812203-1691605812203.png" alt="Pcba development process end goal" class="fr-fic fr-dii"><p>Unclear or unrealistic requirements can be a stumbling block in the PCBA product development process. Poorly defined requirements can lead to misaligned expectations, costly rework, and delays in product delivery. For example, ambiguous specifications for component tolerances may result in incompatible parts, necessitating redesign, and additional costs.</p><p>To avoid this, it is crucial to define clear and realistic requirements that align with the project&rsquo;s end goals. By starting with the end in mind, teams can create a well-defined roadmap for product development and minimize the risk of costly errors.</p><p>Consider the following strategies for defining precise requirements and ensuring stakeholder alignment:</p><ul><li>Conduct Collaborative Requirements Gathering: Identify and gather requirements from all stakeholders, including product owners, engineers, and manufacturers. Requirements must be specific, measurable, achievable, relevant, and time-bound (SMART).</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605812366-1691605812366.png" alt="Document review requirements pcba development" class="fr-fic fr-dii"><ul><li>Document and Review Requirements: Establish a formal requirements document for all stakeholders and conduct a thorough review to ensure that the document is accurate and complete.</li><li>Implement Change Management Processes: During the project, establish a straightforward change management process to handle requirements changes. Communicate changes transparently and promptly to all stakeholders to minimize disruptions.</li></ul><p>By defining clear and realistic requirements and maintaining alignment among stakeholders, teams can confidently and efficiently confidently and efficiently confidently and efficiently navigate the PCBA product development process, ultimately delivering high-quality products that meet the intended objectives.</p><h2>Conclusion</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1691605812020-1691605812020.png" alt="Effecient pcba product development conclusion" class="fr-fic fr-dii"><p>Efficient PCBA product development, though an arduous journey, is well within reach. Teams can overcome challenges and succeed by addressing the five barriers to efficient PCBA product development and implementing the respective solutions.</p><p>Overcoming barriers to efficient PCBA product development involves fostering cross-functional collaboration, integrating early and iterative testing in the development stages, and establishing clear roles and accountability within the team.</p><p>Enhancements such as defining roles in the project charter, using a RACI matrix, and regular status updates streamline execution. Lastly, starting the project with a clear end goal, achieved through collaborative requirements gathering, documentation review, and change management processes, ensures alignment toward the shared objective.</p><p>By employing these product development strategies, teams can facilitate a smoother transition of their product from the initial concept to physical production, all the way through to the product launch. By adhering to these strategies, teams can significantly reduce potential issues or setbacks at each stage of the development process.</p><h4>Discover How MacroFab Will Improve Your Efficiency</h4><p>Upgrade your electronics manufacturing process by leveraging a technology platform that offers differentiated services at every stage, from prototyping to mass production.</p>Visit the <a href="https://www.macrofab.com/electronics-manufacturing-platform/" target="_blank">MACROFAB MANUFACTURING PLATFORM</a> now.&nbsp;</section>

Effective teams are built on open communication

Building open communication within internal teams is the first hurdle. 

Five Barriers to Efficient PCBA Product Development

The acceptance of plastic machining as a manufacturing process is due to the wide array of plastic CNC materials available. Furthermore, with the introduction of computer numerical control, the process becomes more accurate, faster, and suitable for making parts with tight tolerance. How much do you know about plastic CNC machining? This article discusses the materials compatible with the process, available techniques, and other things that can help your project.  

Plastic CNC Machining: Create Custom CNC Machined Parts with Accuracy

<p id="isPasted">The&nbsp;<a href="https://xometry.eu/en/injection-moulding/" target="_blank">injection moulding process</a> is widely used in large volume production as it produces comparatively low scrap production and has high repeatability. The versatility of the injection moulding process demands much broader design considerations. Most of the design considerations will be made on the mould after setting out the product requirements.&nbsp;</p><p>Some of the factors that affect the injection moulding design include: how the part will be used (singular product or for assembly), its dimensional and mechanical requirements, and its ability to withstand elements such as chemicals or pressure. Some vital tips to consider when designing for injection moulding are explored below.</p><p><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe width="640" height="360" src="https://www.youtube.com/embed/i2IwM1_O-T0?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted"><strong>1. Carefully choose materials suitable for your design</strong></h2><p>Different&nbsp;<a href="https://xometry.eu/en/injection-moulding-materials-selection-guide/" target="_blank">injection moulding materials</a> offer varying properties. For example, some injection moulding materials provide more dimensional stability than others. Similarly, some bond better with adhesives than others. Material design considers the following: temperature, pressure, biological and chemical interactions.&nbsp;</p><p>Thermoplastic resins can be broadly classified into <a href="https://en.wikipedia.org/wiki/Crystallization_of_polymers" target="_blank">amorphous and semi-crystalline</a>. While semi-crystalline thermoplastics offer better chemical and electrical resistance, their amorphous counterparts are much more dimensionally stable and more resistant to impact. Material selection can affect the required tolerance level or certain features, like wall thickness.</p><h2 id="isPasted"><strong>2. Take into account the part tolerance</strong></h2><p>Tolerances are affected by the shrinkage that occurs during the cooling process. Amorphous materials like PLA generally have tighter tolerances than semi-crystaline materials like PEEK.&nbsp;</p><p>Tight tolerances make production more expensive, but they may be necessary for your part to fit or function properly, especially if it is used in an assembly.</p><p>We recommend contacting your supplier at the design stage to discuss the tolerance standards that they use.</p><p>For example,&nbsp;<a href="https://www.bopla.de/en/technical-data/technical-information/plastic/general-information-on-plastic-enclosures/tolerances-of-plastics.html" target="_blank">DIN 16901</a> contains a general tolerance table as a reference for different materials. If your supplier uses this standard and you need tighter tolerances or other standards, they will ask you to provide 2D drawings.</p><h2><strong>3. Choose the right wall thickness</strong></h2><p>There are a few key points to consider to ensure you choose the right wall thickness for your injection moulding design:</p><ul><li>Thinner walls shorten the cycle time and lower the cost of your part. For lots of applications a wall thickness of 1.5-2.5 mm is sufficient, but you can also refer to recommended wall thicknesses for different materials</li><li>Unlike CNC machined parts, plastic injection moulded parts benefit from a consistent wall thickness. If a part is thicker in one section than another, a sink mark will appear at that location.</li><li>Non-uniform wall thicknesses also lead to warping, as these walls cool and shrink at different rates. If you require a non-uniform thickness, the change in thickness should not exceed 15% of the nominal wall thickness and should always have a smooth or tapered transition to achieve a high quality part.</li></ul><p>The following are the recommended wall thicknesses for different materials:</p><figure id="isPasted"><table><tbody><tr><td><strong>Material</strong></td><td><strong>Recommended wall thickness</strong></td></tr><tr><td>ABS</td><td>1.143 mm &ndash; 3.556 mm</td></tr><tr><td>Acetal</td><td>0.762 mm &ndash; 3.048 mm</td></tr><tr><td>Acrylic (PMMA)</td><td>0.635 mm &ndash; 12.7 mm</td></tr><tr><td>Liquid Crystal Polymer</td><td>0.762 mm &ndash; 3.048 mm</td></tr><tr><td>Long-Fiber Reinforced Plastics</td><td>1.905 mm &ndash; 27.94 mm</td></tr><tr><td>Nylon</td><td>0.762 mm &ndash; 2.921 mm</td></tr><tr><td>PC (Polycarbonate)</td><td>1.016 mm &ndash; 3.81 mm</td></tr><tr><td>Polyester</td><td>0.635 mm &ndash; 3.175 mm</td></tr><tr><td>Polyethylene (PE)</td><td>0.762 mm &ndash; 5.08 mm</td></tr><tr><td>Polyphenylene Sulfide (PSU)</td><td>0.508 mm &ndash; 4.572 mm</td></tr><tr><td>Polypropylene (PP)</td><td>0.889 mm &ndash; 3.81 mm</td></tr><tr><td>Polystyrene (PS)</td><td>0.889 mm &ndash; 3.81 mm</td></tr><tr><td>Polyurethane</td><td>2.032 mm &ndash; 19.05 mm</td></tr></tbody></table></figure><h2><strong>4. Add draft angles to your design</strong></h2><p><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689922744496-injection-moulding-draft-angles-1440x584.png" style="width: 766px;" class="fr-fic fr-dib"></strong></p><p><span style="background-color: transparent;">Many material removal processes such as CNC machining can produce vertical walls. However, creating a part&rsquo;s design for injection moulding with vertical walls will cause the part to get stuck, particularly at the core, as the part contracts on cooling.</span></p><p>If too much force is applied to eject the part, the risk of damaging the ejector pins and even the mould becomes very high. Design the walls of parts with a slight slant to avoid this problem. This slanting is called a draft.&nbsp;</p><p>Due to the high complexity, it creates in designing, the draft is usually added at the final stages of the part design. Different surfaces require varying drafts. Textured surfaces require the most draft. Some common surfaces found in injection moulding and their minimum draft angles are as follows.</p><ul><li>For &ldquo;near-vertical&rdquo; requirements: 0.5&deg;</li><li>Most common situations: 1 ~ 2&deg;</li><li>All shutoff surfaces: 3&deg;</li><li>Faces with light textures: 1 ~ 3&deg;</li><li>Faces with medium textures: 5&deg;+</li></ul><h2><strong>5. Add ribs and gussets to certain parts</strong></h2><p><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689922780861-ribs-and-gussets-1440x584.png" style="width: 766px;" class="fr-fic fr-dib"></strong></p><p id="isPasted">Certain parts require ribs. Ribs and gussets give additional strength to parts and help to eliminate cosmetic defects like warping, sink and voids. These features are essential for structural components. Therefore, it is preferable to add them to parts rather than increase the thickness of parts to increase strength.&nbsp;</p><p>However, if not properly designed, this can lead to shrinkage. Shrinkage happens when the cooling rate of certain parts is much faster than others, resulting in the permanent bending of some sections. The warping can be effectively reduced by keeping the rib thickness between 50 &ndash; 60% of that of the wall it is attached to.</p><h2><strong>6. Add radii and fillet to part design</strong></h2><p><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689922801486-curved-edges-1440x584.png" style="width: 766px;" class="fr-fic fr-dib"></strong></p><p id="isPasted">Applying radii to parts, when possible, eliminates sharp corners, which improves the flow of material and the part&rsquo;s structural integrity. Sharp corners cause weakness in the part as the molten material is made to flow through the corner or into the corner. The only places where sharp corners are unavoidable are the parting surfaces or shut-off surfaces.&nbsp;</p><p>Radii and fillets also aid in a part ejection as rounded corners are less likely to get stuck during ejection than sharp corners. Furthermore, sharp corners are also not structurally advisable as they lead to stress points that can fail. Radii help to smoothen out the stress on the corners.&nbsp;</p><p>Also, including sharp corners in your part will exponentially increase the cost of production as this would require the mould to feature sharp corners that can only be achieved using very expensive manufacturing techniques.</p><p>Add internal radii at least 0.5 times the thickness of the adjacent wall and external radii 1.5 times the size.</p><h2><strong>7. Avoid undercuts and provide slots where possible</strong></h2><p><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689922822294-slot-injection-moulding-1440x584.png" style="width: 766px;" class="fr-fic fr-dib"></strong></p><p id="isPasted">Snap fits are obtainable through undercuts. The straight-pull mould, which consists of two halves, and is the most straightforward design, is not suitable to manufacture parts with undercut features. This is due to the difficulty in machining such a mould with CNC and the tendency of the material to get stuck on ejection.</p><p>Undercuts are usually created using side cores. However, side cores significantly increase tooling costs. Luckily there are some design tips to achieve the function of an undercut without using side cores. One way of doing this is by introducing a slot instead.&nbsp;</p><p>This is also referred to as a pass-through core. Another way is to adjust or move the parting line of the part. When doing this, also adjust the draft angle accordingly. Moving the parting lines is most suitable for undercuts that are on the outside of the part.</p><p>You can also use stripping undercuts, also referred to as bump offs. However, only use this feature when the part is flexible enough to deform and expand during ejection from the mould.</p><p><strong>Also, give enough clearance</strong>: bump-offs must have a lead angle of 30&deg; to 45&deg; for effective ejection. All these alternatives to expensive side cores require significant redesigning of the part. When the redesign of a part is not possible due to the possibility that it may affect the functionality of the part, then you have to employ sliding side-actions and cores to deal with undercuts.</p><p>These features slide in as the mould closes and slide out as it opens. The side cores must move perpendicularly and have appropriate draft angles.</p><h2><strong>8. Attach bosses to side walls or ribs</strong></h2><p><strong><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1689922863149-ribs-and-gussets-injection-moulding-1440x584.png" style="width: 766px;" class="fr-fic fr-dib"></strong></p><p id="isPasted">Bosses are cylindrical standoffs moulded into a plastic part to accept an insert, self-tapping screw, or pin for assembling or mounting parts.</p><p>The outer diameter (OD) of the boss should be 2.5 times the diameter of the screw diameter for self-tapping applications.</p><p>Bosses shouldn&rsquo;t be freestanding. Always attach bosses to a side wall or to the floor with ribs or gussets. Their thickness should not exceed 60% of the overall part thickness to minimize visible sink marks on the outside of the part.</p><p>For example, a part with an outer wall of 3 mm should have internal ribs that are no more than 1.7 mm thick.</p><h2><strong>9. Gating: Highlight visually important surfaces on your part where there must not be any marks</strong></h2><p>In order to properly design and manufacture your part using injection moulding, it is important for the manufacturer to understand from the outset what your requirements are in terms of its appearance. &nbsp;</p><p>One key point for the tool maker to consider is the gate location. Gates are entry sections through which the molten material enters the mould. The tool maker has to choose the type of the gates and position them strategically to minimize potential quality issues.&nbsp;</p><p>Gates also leave gate vestige or a visual indication that the part was gated&mdash;even if it is subtle.</p><p>That&rsquo;s why we recommend letting your supplier know about any aesthetic and functional requirements and defining where not to gate.</p><h2 id="isPasted"><strong>Design your parts for injection moulding and source them with Xometry</strong></h2><p>At Xometry Europe, we offer&nbsp;<a href="https://xometry.eu/en/injection-moulding/" rel="noreferrer noopener" target="_blank">injection moulding services</a> with over 30 materials, such as plastics, synthetic and silicone rubber, and elastomers. Simply head over to our&nbsp;<a href="https://my.xometry.eu/quote?locale=en" rel="noreferrer noopener" target="_blank">Quoting Engine</a> to upload your model and select your part preferences to receive a 24h quote.</p>

This article sums up the best practices for designing injection moulding to help you get quality polymer parts at a reasonable cost.

Design Tips for Injection Moulding

<section id="isPasted"><p>Climate change is becoming more widely recognized, and companies are expected to act. Businesses now face growing demands from investors, customers, and regulators to decrease their carbon footprint and be more environmentally responsible.</p><p>ESG (Environmental, Social, and Governance) initiatives, once little more than a buzzword, have increasingly become crucial to a business&rsquo;s success and longevity.</p><p>But the electronics manufacturing industry is one of the largest energy and resource consumers globally, responsible for two percent of global greenhouse gas emissions. The production of semiconductors, in particular, contributes significantly to the industry&rsquo;s carbon footprint due to its reliance on fossil fuels and water-intensive processes.</p><p>So, how can electronics manufacturers address these issues while maintaining their competitive advantage and profitability?</p><p>The solution is to adopt ESG (Environmental, Social, and Governance) initiatives that benefit both their businesses and stakeholders. In this article, we will explore five critical ways in which ESG elements can benefit the PCBA (printed circuit board assembly) industry and the benefits, challenges, and importance of implementing ESG initiatives.</p><h2>Understanding ESG Elements in the Electronics Manufacturing Industry</h2><p>To better understand how ESG investment can create value, it is crucial to introduce the three ESG elements: environmental, social, and governance, and how they impact business practices and their stakeholders.</p><h3>Environmental Criteria</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587169507-1688587169507.png" alt="Esg environmental criteria" class="fr-fic fr-dii"><p>The environmental criteria in ESG initiatives refer to factors related to the company&rsquo;s impact on the environment. This includes the company&rsquo;s carbon footprint, greenhouse gas emissions, waste generation, energy consumption, water usage, and overall ecological impact. The goal of environmental criteria is to ensure that companies operate in a manner that minimizes their negative impact on the environment while contributing to a sustainable future.</p><p>The electronics manufacturing industry consumes significant energy and resources, which contributes to environmental degradation. Implementing eco-friendly manufacturing practices that focus on the impact on the natural world can significantly reduce the industry&rsquo;s carbon footprint.</p><p>As an example, recycling electronic waste and using renewable energy solutions such as solar, wind, or geothermal can reduce waste generation and conserve resources.</p><h3>Social Criteria</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587169718-1688587169718.png" alt="Esg social criteria" class="fr-fic fr-dii"><p>The social criteria in ESG initiatives refer to the factors related to a company&rsquo;s impact on society. The social element examines how a business treats its employees, customers, suppliers, and communities, ensuring provisions for safe and healthy working conditions. It must also adhere to labor laws, prevent discrimination and harassment, and provide fair wages and benefits to its employees.</p><p>Additionally, electronic products must be <a href="https://www.macrofab.com/blog/component-obsolescence" target="_blank">designed with end-of-life management in mind</a> to ensure they do not harm the environment or pose a risk to society. Corporate social responsibility builds trust, enhances reputation, and strengthens relationships with stakeholders.</p><h3>Governance</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587169683-1688587169683.png" alt="Esg governance" class="fr-fic fr-dii"><p>Last but not least, governance criteria refer to the factors related to a company&rsquo;s management and decision-making processes. The governance criteria are essential to ensure that a company operates in a responsible and sustainable manner while creating long-term value for its stakeholders by emphasizing transparency and accountability in business operations.</p><p>This includes identifying and mitigating ESG risks, such as regulatory compliance and operational disruption, as well as preventing corruption or bribery in operations and supply chains. The effectiveness of the company&rsquo;s governance ensures its long-term value for shareholders. By addressing governance criteria, a company can build credibility, enhance transparency, and improve its financial performance.</p><p>It is well-known that addressing ESG concerns can provide significant value for businesses and stakeholders. This is evidenced by the fact that companies that prioritize ESG initiatives tend to have higher equity returns, lower downside risk, higher credit ratings, and better valuation. For instance, Siemens is a company that has set ambitious targets for reducing carbon emissions, increasing energy efficiency, and supporting social causes. In 2021, the company&rsquo;s revenue increased by sixteen percent from the previous year, reaching over $74 billion.</p><h2>Five Ways ESG Initiatives Create Value</h2><p>ESG initiatives are crucial for the electronics manufacturing industry as they create value by attracting new customers, reducing costs, limiting risks, and increasing employee productivity. Here are five key ways that ESG initiatives benefit the electronics manufacturing industry:</p><h3>Driving Revenue Growth</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587169630-1688587169630.png" alt="Driving revenue growith retail" class="fr-fic fr-dii"><p>Adopting ESG initiatives can open up new revenue streams for the electronics manufacturing industry. For instance, the growing demand for eco-friendly products presents an opportunity for companies to develop sustainable products that meet consumer needs.</p><p>In addition to the benefits outlined, companies within the electronics industry that implement ESG initiatives can also tap into a growing market of environmentally-conscious consumers. These consumers are increasingly prioritizing the environmental impact of the products they purchase, and are more likely to support companies with strong environmental policies.</p><p>By adopting sustainable practices and demonstrating a commitment to environmental responsibility, electronics companies can attract these customers and expand their customer base, while also contributing to a more sustainable future.</p><p>According to Harvard Business Review research, strong ESG performance can increase a company&rsquo;s market share by six percent. In addition, Forbes found that 88 percent of consumers prefer to buy products from companies that support social or environmental causes.</p><h3>Reducing Costs</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587171187-1688587171187.png" alt="Esg reducing costs" class="fr-fic fr-dii"><p>ESG initiatives can also help companies in the PCBA industry reduce costs. For instance, implementing energy-efficient practices can reduce energy consumption, leading to lower operational costs. Further, recycling electronic waste can help reduce waste disposal costs while also conserving natural resources.</p><p>In 2021, McKinsey reported that companies with strong ESG performance reduced costs by 5 to 10 percent. Cost reductions were due to several factors, including increased efficiency, reduced waste, and improved risk management.</p><h3>Increasing Employee Productivity</h3><p>ESG initiatives can also positively impact employee productivity. Employees who work for companies that value ESG principles are more engaged and motivated. In addition, companies prioritizing ESG initiatives often have better employee retention rates and lower employer absenteeism. This can significantly reduce costs related to training and onboarding.</p><p>Companies benefit from ESG initiatives and strong labor relations. According to Glassdoor, 77 percent of job seekers consider a company&rsquo;s culture before accepting an offer. Harvard Business Review also found that companies with strong labor relations have a 20 percent higher productivity.</p><a href="https://www.macrofab.com/blog/esg-create-value-pcba-industry/#" target="_blank" title="click to enlarge"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587171225-1688587171225.png" alt="Recruiting needs mission minded chart" class="fr-fic fr-dii"></a><h3>Optimizing Investment and Capital Expenditures</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587170186-1688587170186.png" alt="Optimize investment capital expenditures" class="fr-fic fr-dii"><p>Investors increasingly focus on companies prioritizing ESG initiatives. By implementing ESG initiatives, the PCBA industry can attract more investors and optimize its investment and capital expenditure strategies. Companies may invest in renewable energy solutions to reduce their dependence on fossil fuels and reduce energy costs, or in sustainable products and technologies to ensure their long-term success.</p><p>ESG performance is associated with a 5.4 percent return on equity, according to McKinsey, while CDP reports a 67 percent higher return on investment for companies that manage water sustainably. Further, S&amp;P Global found that companies with higher ESG scores had lower debt costs. Examples include energy-efficient equipment, renewable energy, and waste management.</p><h3>Minimizing Legal and Regulatory Impacts</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587171014-1688587171014.png" alt="Compliance regulation" class="fr-fic fr-dii"><p>The electronics manufacturing industry is subject to several regulations and laws that aim to protect the environment and society. However, companies that implement ESG initiatives can proactively mitigate regulatory and legal interventions. For example, companies that comply with environmental regulations are less likely to face legal and financial penalties.</p><p>However, companies that adopt sustainable practices often avoid potential legal and regulatory risks entirely, while at the same time minimizing reputational risks that can impact their bottom line.</p><h2>Challenges of Implementing ESG Initiatives</h2><p>While implementing ESG initiatives has several benefits for the electronics manufacturing industry, they are not without challenges. Here are three key challenges that the PCBA industry might face when implementing ESG initiatives.</p><h3>No Unified Regulations</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587170983-1688587170983.png" alt="Regulatory compliance" class="fr-fic fr-dii"><p>While the electronics manufacturing industry must adhere to several regulations and laws, there are still no comprehensive regulations that require companies to implement ESG initiatives. While some countries and regions have introduced rules, the standards can vary widely across jurisdictions, creating confusion for companies operating across borders.</p><p>For example, in the United States, no federal mandate requires companies to disclose their ESG practices, although many states have enacted their own legislation. This lack of framework makes it difficult for investors and stakeholders to assess a company&rsquo;s ESG strategy.</p><p>Thus, companies may hesitate to invest in sustainable practices, especially in regions with minimal regulatory requirements, seeing them as an unnecessary financial burden.</p><h3>Implementation Costs</h3><p>Implementing ESG initiatives can also be costly, particularly for small and medium-sized businesses. An average company spends $30 million implementing sustainability initiatives, according to a Deloitte report. This can be a barrier for some that can&rsquo;t afford the upfront costs of investing in ESG initiatives.</p><p>Implementing energy-efficient practices may require companies to invest in new equipment, which can be expensive. In addition, fair labor practices can increase labor costs, affecting the company&rsquo;s profitability.</p><p>However, it is essential to recognize that the benefits of ESG initiatives often outweigh the costs. Moreover, ESG offers a variety of options for planning under uncertainty, as well as unlocking value and reducing bottlenecks during net-zero decarbonization, as demonstrated in a 2022 McKinsey report.</p><a href="https://www.macrofab.com/blog/esg-create-value-pcba-industry/#" target="_blank" title="click to enlarge"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587171150-1688587171150.png" alt="Net zero transition chart" class="fr-fic fr-dii"></a><h3>Changing Cultural Attitudes</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587170270-1688587170270.png" alt="Changing cultural attitudes" class="fr-fic fr-dii"><p>Implementing ESG initiatives may require a cultural change within the company. For instance, employees may need to change their behavior to support eco-friendly practices, which may take time and effort. According to a survey by BCG, 70 percent of executives believe that the biggest challenge in implementing ESG initiatives is changing their corporate culture. Companies may also need to completely rethink their business models to incorporate sustainable practices, which may take time and prove challenging.</p><p>The benefits of creating a sustainable culture are significant. According to a study by PwC, companies with a clear sense of purpose are 2.5 times more likely to be considered top performers. Additionally, PCBA companies can gain support from all stakeholders by integrating environmental, social, and governance initiatives into their business practices as part of a culture of sustainability.</p><h2>Conclusion</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1688587170141-1688587170141.png" alt="Esg" class="fr-fic fr-dii"><p>ESG factors are critical for the electronics manufacturing industry&rsquo;s long-term growth and sustainability. Adhering to environmental, social, and governance criteria can help the industry reduce costs, minimize legal and regulatory interventions, improve employee productivity, and optimize investment and capital expenditures.</p><p>However, implementing ESG initiatives can pose several challenges, such as a lack of comprehensive regulations, implementation costs, and the need for cultural change. Nonetheless, the benefits of implementing ESG initiatives far outweigh the costs and challenges, and it is crucial for the electronics manufacturing industry to adopt sustainable practices to ensure long-term success and profitability.</p><p>If the electronics manufacturing industry is to be successful and sustainable over the long haul, it must prioritize ESG initiatives. By adhering to environmental, social, and governance criteria, the industry can create long-term value for its internal and external stakeholders and ensure that its operations are sustainable and responsible.</p><h4>Want to know more about ESG initiatives?</h4><p>Read MacroFab&#39;s White Paper <a href="https://www.macrofab.com/documents/sustainability-challenges-electronics-manufacturing/" rel="noopener noreferrer" target="_blank">Navigating Sustainability Challenges in Electronics Manufacturing</a>&nbsp;now.&nbsp;&nbsp;</p></section><section><h4><br></h4></section><p><br></p>

Companies with strong ESG performance reduce costs by 5 to 10 percent. 

How ESG Initiatives Create Value for the PCBA Industry

<p id="isPasted">To excel in the fast-paced electronics industry, you need not just adaptability, but a cultivated expertise to discern the far-reaching impact of your design decisions. This eBook is your key to building such expertise.</p><p>&quot;Engineering Essentials: The PCBA Design Handbook&quot; equips you with the skills necessary to create exceptional PCBAs that consistently surpass expectations while keeping to stringent deadlines and budgets. From the basic principles of PCBA design to the most sophisticated techniques and best practices, this 75-page resource is your secret weapon to conquer even the most intricate design challenges.</p><p>Dive into the insightful chapters of our eBook and uncover:</p><p>Designing for Manufacturability: Master techniques to optimize your designs, streamline manufacturing processes, and effectively reduce costs.</p><p>Designing for Reliability: Learn the art of crafting robust PCBAs that thrive in harsh environments and offer unwavering performance.</p><p>Designing for Testability: Incorporate efficient built-in testing methods to accelerate production and enhance fault detection.</p><p>Designing for Compliance: Navigate the roadmap to ensure your designs comply with industry regulations and standards effortlessly.</p><p>Designing for EMC Compliance: Delve into the principles of electromagnetic compatibility and effectively minimize interference in your PCBA designs.</p><p>Designing for PCBA Lifespan: Unearth strategies to extend the life and performance of your PCBAs through smart design choices.</p><p>Begin your reading journey today, and harness the full spectrum of your electrical engineering potential today.</p><p>Here is the first section:&nbsp;</p><h2>Designing for Manufacturability: Design Techniques and Best Practices</h2><p>Design complexity is a daily reality for most PCBA designers, making their jobs increasingly difficult and challenging. This complexity extends beyond design, leading to intricate manufacturing hurdles.&nbsp;</p><p>Selecting a contract manufacturer that aligns with your design needs is crucial, as every product is unique and quality hinges on a compatible factory. A mismatch can result in manufacturing issues that can persist long after product shipment, causing unfulfilled warranty expectations, financial strain, or even loss of market share.&nbsp;</p><p>Design is a crucial element in the manufacturing and assembly process, and implementing effective strategies can make all the difference. While &ldquo;design for manufacturability&rdquo; (DFM) is a known concept, it is sometimes underappreciated or underutilized by electrical engineers.&nbsp;</p><p>Design for Manufacturability (DFM) is a proactive approach to designing products that can be consistently manufactured by the designated supply chain with minimal defects. A DFM approach combines best practices with a keen awareness of supply chain limitations, and it can improve the efficiency and quality of manufacturing.&nbsp;</p><p>By embracing DFM in the design process, electrical engineers can sidestep common problems like high production costs, low yields, extended lead times, and component shortages that tend to surface when DFM is neglected.&nbsp;</p><p>The purpose of this section is to provide electrical engineers with a deeper understanding of PCBA design guidelines and DFM best practices.&nbsp;</p><h3>Best Practices for PCBA Design</h3><p>To create high-quality, cost-effective, and easily manufactured PCBAs, it&rsquo;s essential to adhere to certain design guidelines that are critical for manufacturability. These include</p><p><strong>Component Placement and Selection&nbsp;</strong></p><p>Choosing the right components for your PCBA is crucial for long-term reliability and performance. When selecting components, be sure to:</p><ul><li>&nbsp;<strong>Opt for standard components</strong>: Avoid unique or rare components, which may lead to higher costs, limited supplier competition, and increased supply chain disruptions. Standard components are more costeffective, have a proven track record, and have shorter lead times for better on-time product delivery.&nbsp;</li><li><strong>Conduct a Bill of Materials (BOM) analysis</strong>: A streamlined BOM can help reduce manufacturing costs. Fewer parts result in less purchasing activity, lower inventory needs, simplified inspections, and easier testing protocols. Careful creation and review of the BOM are essential to achieve this. &nbsp;</li><li><strong id="isPasted">Use multi-functional parts</strong>: Choose components that serve multiple purposes, such as a cover or base plate that also functions as a heat sink.</li><li>&nbsp;<strong>Account for Moisture Sensitivity Level (MSL)</strong>: Identify the MSL for all components and ensure the exposure time on the production floor is controlled. This helps prevent moisture-induced damage to sensitive components.&nbsp;</li></ul><p><strong>Improve PCBA Design with Lean Processes&nbsp;</strong></p><p>As you tackle your PCBA design, remember to prioritize efficiency. Remove any unnecessary steps or elements that don&rsquo;t contribute to your product&rsquo;s overall quality or function. By simplifying the supply, fabrication, and assembly processes, you&rsquo;ll not only increase accuracy and speed but also make your PCBA easier to manufacture.&nbsp;</p><ul><li><strong>Use consistent traces</strong>: Use consistent trace widths and avoid overly complex routing patterns to facilitate a smooth and easy manufacturing and inspection process</li><li><strong>Optimize component placement</strong>: Choose careful component placement to minimize trace lengths and reduce the chance of signal interference&nbsp;</li><li><strong>Collaborate with manufacturers:</strong> Engage in early and ongoing communication with your CM to ensure design compatibility and address potential issues to improve and enhance manufacturability.&nbsp;</li></ul><p><strong>Optimize Trace Routing and Layout&nbsp;</strong></p><p>Some key aspects to consider while optimizing trace routing and layout are:&nbsp;</p><ul><li><strong>Trace Widths and Spaces</strong>: Choose trace widths and spaces according to the guidelines provided by IPC-2221 to ensure the efficient distribution of electrical signals and reduce signal interference.&nbsp;</li><li><strong>Layer Stackup</strong>: Design a balanced layer stack-up that promotes efficient signal routing and thermal management, considering factors such as signal integrity and power distribution.</li><li><strong>Routing Techniques</strong>: Implement appropriate routing techniques, such as using differential pairs, controlled impedance traces, and avoiding 90-degree angles, to maintain signal integrity and reduce the possibility of electromagnetic interference (EMI).</li><li><strong>Ground and Power Planes</strong>: Design solid ground and power planes to provide adequate electrical and thermal performance while minimizing noise and crosstalk.&nbsp;</li><li><strong>Design for Signal Integrity</strong>: Consider factors such as trace impedance, trace length matching, and proper termination to ensure the signals maintain integrity throughout the circuit.&nbsp;</li></ul><p>Get the complete <a href="https://www.macrofab.com/documents/pcba-design-handbook-2023/" rel="noopener noreferrer" target="_blank">Engineering Essentials: The PCBA Design Handbook</a> now.&nbsp;</p><p><br></p>

This 75-page e-book will provide you with the design skills to develop exceptional PCBAs that not only meet but surpass their intended objectives. 

Engineering Essentials: The PCBA Design Handbook

<section id="isPasted"><p>In electronics, counterfeiters have become more sophisticated, making it difficult for companies to identify fraudulent parts. In the midst of the shift, electronics developers face major challenges, particularly as they recover from a period when traditionally-sourced components were difficult to find.</p><p>Experts believe that counterfeit goods cost the global economy as much as $250B every year. It was reported in 2011 that 15% of the spare and replacement parts purchased by the Pentagon were counterfeit, not only jeopardizing national security but possibly putting American lives at risk.</p><p>Today, one in ten IT products sold may be counterfeit. It is common for counterfeit products to enter the legitimate sales stream; in fact, about two-thirds of counterfeit electronics are sold by reputable companies, with little awareness of the problem.</p><h2>How do Counterfeit Parts Get Purchased?</h2><p>As a result of the complex and opaque nature of the electronics supply chain, counterfeit parts can be integrated into circuit boards in a variety of ways. This is due to a number of factors, including</p><ul><li><strong>Supply chain complexity.</strong> Multi-tier supply chains make it difficult to understand where parts originate from.</li><li><strong>Lack of quality control.</strong> Leaving testing and quality control to others can result in undesirable results. By enforcing proper QC standards, counterfeit electronic parts can be avoided.</li><li><strong>Time pressures.</strong> Buying parts under time pressure may lead some to consider buying from unvetted sources.</li><li><strong>Availability issues.</strong> During periods of shortage, counterfeit parts may become the only option available. Many may fall into the trap of believing that what they don&rsquo;t know can&rsquo;t harm them.</li><li><strong>Cost.</strong> The cost-conscious buyer finds counterfeit parts appealing because they are usually cheaper than genuine parts.</li><li><strong>Misrepresentation.</strong> Often, fake parts look and behave just like the real thing, so it is difficult for buyers to distinguish between the two. Sometimes visual inspections can prevent counterfeits, but other times electrical testing or X-ray inspection are required.</li></ul><p>As counterfeits have become more prevalent, engineers are being asked to do more to prevent them from entering product builds. In this article, we&rsquo;ll first touch on why counterfeit components are a serious problem for modern electronics developers. Then we&rsquo;ll discuss ways to avoid counterfeit components in electronics manufacturing across product development.</p><h2>The Dangers of Counterfeit Components</h2><p>Counterfeit components are dangerous to companies and consumers for several reasons. These reasons include:</p><ul><li>Increased rate of product failures</li><li>Safety hazards</li><li><a href="https://www.macrofab.com/documents/engineers-guide-pcb-manufacturing-intellectual-property" target="_blank">Intellectual property infringement</a> (IP)</li><li>Loss of revenue</li></ul><p>Therefore, avoiding counterfeit components is not only financially beneficial &ndash; it&rsquo;s paramount for long-term enterprise success. Let&rsquo;s take a closer look at each issue.</p><h3>Product Failures</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686845486809-1686845486809.png" alt="Product failures sparks" class="fr-fic fr-dii"><p>One of the more obvious downsides of counterfeit components is that they lead to product failures. This poses a commercial risk to business customers who depend on these products to deliver their own services. Moreover, it poses a financial risk to the company developing the technology because of reputational damage, litigation, warranty claims, and recall expenses.</p><p>To offset product failures caused by counterfeits, companies must produce higher volumes of goods in exchange for no incremental gain. Production efficiency comes down, and procurement teams must source additional components within a short period of time, which may further increase the chance that counterfeits enter the process. Such product failures lead to increased production costs and decreased profit margins as the company absorbs costs associated with fixing problems caused by counterfeit parts.</p><h3>Safety Hazards</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686845486518-1686845486518.png" alt="Laptop on fire" class="fr-fic fr-dii"><p>Depending on the nature of a product, counterfeit components can cause physical harm to users. Take counterfeit laptop batteries, for example. These parts can overheat and ignite, posing a clear threat to unsuspecting users and even to factory workers on production lines.</p><p>Additionally, the use of counterfeit components in medical devices and equipment can pose a serious risk to patient health and safety, as these products are used in critical medical procedures and treatments. In the worst-case scenario, the failure of a counterfeit component could result in serious injury or death, further emphasizing the importance of ensuring the quality and authenticity of all components used in these products.</p><p>In the third quarter of 2022, the number of US product recalls across all categories reached a 20-year high, according to Sedgwick Claims Management. As part of this report, the FDA provided guidance on how to protect advanced medical technology from cyberattacks, which could result in the death of a patient. There is a real and growing problem here.</p><h3>Intellectual Property Infringement</h3><p>Counterfeiting also falls under the IP infringement umbrella. IP theft is already a huge issue in the electronics world. Many countries, like China, don&rsquo;t offer robust IP protections like the U.S., Canada, and Mexico do. Counterfeit parts can alter the final performance of a product, thereby deceiving consumers and detracting from the original intention of a product&rsquo;s design.</p><h3>Loss of Revenue</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686845486721-1686845486721.png" alt="Trusted brand logo" class="fr-fic fr-dii"><p>Counterfeiting is a major issue for electronics companies and can lead to significant financial losses. The use of counterfeit parts can result in product failure, which can have a negative impact on a company&rsquo;s reputation and brand image.</p><p>Faulty counterfeit electronics can make customers lose trust in a brand, leading them to switch to competitor products. This leads to a decrease in sales and top-line revenue for the company, which can have a domino effect on the company&rsquo;s financial performance.</p><p>The decrease in sales can impact a company&rsquo;s operating margin, making it more difficult for the company to invest in high-quality electronics. This can further erode the company&rsquo;s competitiveness, leading to a continuation of the downward spiral.</p><p>With fewer customers choosing their products, the company may struggle to maintain its market position, leading to long-term financial losses and a reduction in overall revenue.</p><h2>Where Counterfeits Cause Harm</h2><p>Counterfeits cause harm in three specific areas related to the electronics production process:</p><ul><li>Engineering design workflow</li><li>Product viability</li><li>Enterprise reputation</li></ul><p>All three must be protected to ensure maximum product performance and efficiency.</p><h3>Engineering Design Workflow</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686845486686-1686845486686.png" alt="Engineering design workflow agile" class="fr-fic fr-dii"><p>The engineering design workflow should be transparent, collaborative, and proactive. Stakeholders across the product development lifecycle should be in regular communication about marketplace conditions, enterprise goals, and current developments. This is how production remains agile and resilient in the age of disruption.</p><p>But counterfeit parts add chaos to the equation. They force teams to take shortcuts and go outside their standard operating procedures, increasing risk dramatically.</p><h3>Product Viability</h3><p>The use of counterfeit parts can also pose a risk to a product&rsquo;s viability. It&rsquo;s challenging to determine whether a product meets market demand and customer expectations when counterfeit parts are present within the design. A counterfeit part is more likely to fail, so it increases the likelihood of a product malfunctioning.</p><p>With the presence of counterfeit components, it becomes difficult to accurately assess the product&rsquo;s success, as the product&rsquo;s reliability and performance have been compromised.</p><h3>Enterprise Reputation</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686845486640-1686845486640.png" alt="Enterprise reputation" class="fr-fic fr-dii"><p>Finally, counterfeit components can hurt a company&rsquo;s reputation. As alluded to previously, counterfeit parts lead to more product failures and safety hazards. When a product fails to fulfill its intended function, it is a mark against the company. And in the modern era, this information spreads quickly.</p><p>It&rsquo;s getting harder for organizations to protect their reputations, and few enterprises work within markets free from competition. With so much data and so many substitute products available, it&rsquo;s easier for potential customers to find a replacement product. The process of repairing a tarnished reputation is time-consuming, expensive, and difficult. Counterfeit components can set an electronics business back and even catalyze its downfalls.</p><h2>How to Keep Counterfeit Components out of Company Designs</h2><p>For all the reasons above, engineers involved in the electronics design process must take an active role in blocking counterfeit components from entering the production process. This primarily includes design, component, and purchasing engineers.</p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686845486762-1686845486762.png" alt="Keep counterfeit components out of designs" class="fr-fic fr-dii"><p>Especially for products with short life cycles, design engineers can reduce counterfeit risk by incorporating flexibility and modularity into designs. The more flexible and modular a design is, the easier it is to slot in a replacement part when the end-of-life stage approaches or if counterfeits find their way into production. As a result of a proactive approach like this, counterfeit components have less impact on the final outcome.</p><p>Component engineers can also mitigate counterfeit risk by informing design engineers of component options, alternatives, and availability. Knowing what&rsquo;s on the market and planning ahead allows component engineers to make sure their organizations use reliable and accessible parts. They prevent businesses from having to make difficult future decisions should component supply dry up.</p><p>Additionally, purchasing engineers or procurement specialists should use authorized suppliers and allow sufficient time to conduct a thorough purchase process. While this isn&rsquo;t always possible, encouraging component and design engineers to share designs early can alleviate the need for purchasers to explore options outside of trusted channels.</p><p>Partnering with an experienced supplier or trusted contract manufacturer who can also source components safely makes sense, as well, and provides a <a href="https://www.macrofab.com/documents/modern-strategic-sourcing-principles" target="_blank">safe procurement</a> channel. The key here is to look for organizations with <a href="https://www.erai.com/" target="_blank">ERAI membership</a> that have access to risk assessment tools and reports on the current counterfeit marketplace. MacroFab is a proud member of ERAI.</p><p>There is a real and growing threat of counterfeit products in the electronics industry. To address this issue, design engineers, component engineers, and purchasing engineers must take proactive measures to ensure that the components used in their products are authentic. From implementing stricter supplier selection criteria to utilizing technology for product traceability, these key players can play a significant role in keeping counterfeit parts out of the supply chain and ensuring the quality and reliability of end products.</p><h4>Learn More About Reducing Counterfeits in PCBA</h4><p><strong>Watch the On-Demand Webinar:</strong></p><p>How to Maximize PCBA Design Efficiency with Reduced Redesign</p><a href="https://www.macrofab.com/webinars/maximize-pcba-design-efficiency" target="_blank">WATCH NOW</a></section><section><br></section>

Counterfeit parts can derail your project fast 

There is a real and growing threat of counterfeit products within the electronics industry.  Do you know how to mitigate it? 

For Engineers, Counterfeit PCBA Parts Pose New Challenges

<section id="isPasted"><p>Component obsolescence is a major challenge for industries relying on electronics. Electronic parts go out of date fast - two to five years on average - and 15 percent disappear from the market annually. Outdated components harm product quality, reliability, and profitability, forcing several times more expensive due to limited supply, demand, counterfeit risks, or redesign. Thus, proactive obsolescence management, starting with product design, is crucial.</p><p>In this article, we will explore some of the reasons for component obsolescence, some of the best practices for managing it effectively, and some of the benefits of partnering with a supply chain expert who can help you mitigate obsolescence risks and maximize product value.</p><h2>Reasons for Component Obsolescence</h2><p>It is essential to understand the <a href="https://www.macrofab.com/blog/component-obsolescence/" target="_blank">factors contributing to component obsolescence</a>, which is a growing challenge for companies within the electronics industry.</p><p>One significant reason for component obsolescence is the rapid pace of technological innovation and development in the industry. This trend is shortening the life cycles of integrated circuits (ICs) by an average of 30 percent. A study by S&amp;P Global Market Intelligence revealed that over 50 percent of ICs have a lifespan shorter than five years.</p><p>Another contributing factor is the increasing consolidation and competition in the upstream supply chain through mergers and acquisitions (M&amp;A). This trend has led to more end-of-life (EOL) notifications and faster product life cycle changes. In fact, M&amp;A activity is currently affecting over 200 billion components worldwide, according to IHS Markit.</p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MDU1NDIyMDc4LTE2ODYwNTU0MjIwNzgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Consumer demand electronics" class="fr-fic fr-dii"><p>Additionally, consumer demand for newer and smarter electronic products is driving more frequent upgrades and replacements of existing devices. For example, a recent survey by Accenture found that 47 percent of consumers plan to replace their smartphones every year or sooner.</p><p>Changes in government regulations and environmental standards also have a significant impact on component availability and compatibility. The Restriction of Hazardous Substances (RoHS) directive, for instance, prohibits the use of certain substances such as lead, mercury, or cadmium in electrical and electronic equipment sold in the European Union.</p><p>These factors pose significant challenges for companies that must ensure product designs are functional, reliable, compatible, compliant, and profitable throughout their intended life span. As an industry professional, it is crucial to keep up with these trends and their implications to make informed decisions about product design and component selection.</p><h2>Best Practices for Managing Component Obsolescence</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MDU1NDIyMTE1LTE2ODYwNTU0MjIxMTUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Best practices managing component obsolescence" class="fr-fic fr-dii"><p>To avoid or minimize the negative impact of component obsolescence on products and systems, it&rsquo;s essential to adopt an obsolescence management strategy during the product design phase. This involves incorporating best practices such as specifying components with long-term availability or multiple sources, leveraging production and order history to anticipate component turnover, communicating with end users to align design with customer expectations, maintaining regulatory compliance, and incorporating design-for-obsolescence strategies to ensure product longevity.</p><p>To reduce the risk of sourcing difficulties and price fluctuations due to limited supply or high demand, specify components that have long-term availability or have multiple sources for all necessary parts. For instance, choose to use components that are commonly found in other industries like automotive or aerospace, to ensure a stable supply chain. While this creates competition for their purchase, it also ensures they remain readily available, typically from multiple sources, as long as they remain in high demand. When you can&rsquo;t use these strategies, use best practices to <a href="https://www.macrofab.com/blog/reducing-single-source-component-risk" target="_blank">reduce single-source component risks</a>.</p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MDU1NDIyMDM3LTE2ODYwNTU0MjIwMzcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Leverage order production history data" class="fr-fic fr-dii"><p>Leverage production and order history data to gain visibility into component turnover rates and identify parts that are at risk of becoming obsolete or slow-moving. Plan accordingly for inventory management or replacement strategies. Additionally, use data analytics to monitor the usage and performance of components and forecast their life expectancy to stay ahead of potential obsolescence. MacroFab&rsquo;s technology platform is ideally suited to provide this sort of analytical data.</p><p>Communicating with end-users to understand their needs and expectations regarding product longevity is crucial in ensuring that product design aligns with their requirements. By preventing premature obsolescence, unnecessary costs and dissatisfaction can be avoided.</p><p>Maintaining regulatory compliance requirements and forecasting their impact on parts in stock and production is essential in ensuring regulatory adherence, avoiding penalties or fines, and anticipating potential component availability or compatibility changes.</p><h2>Options to Consider at the Design Stage</h2><p>Design-for-obsolescence strategies such as modularization, standardization, upgradability, and reusability can enhance product flexibility, adaptability, and maintainability, ultimately extending product life span. Below are explanations of each strategy and how to use it:</p><p><strong>Modularization:</strong> This strategy involves designing products as a series of independent modules that can be easily replaced or upgraded. By doing so, end users can replace only the faulty or outdated module instead of buying a completely new device. This results in cost savings for the end user and reduces electronic waste. To implement modularization, design teams should identify the components that are most likely to become obsolete and design them as interchangeable modules.</p><p><strong>Standardization:</strong> This strategy involves using standard components and interfaces that are compatible with other products. For example, using USB ports for charging and data transfer instead of proprietary connectors. Standardization allows for greater interoperability between products, making it easier for end-users to replace or upgrade components. This strategy also makes it easier for manufacturers to source components and will ultimately reduce costs.</p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MDU1NDIyMjI1LTE2ODYwNTU0MjIyMjUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Upgrade ram" class="fr-fic fr-dii"><p><strong>Upgradability:</strong> This strategy involves designing products with the ability to upgrade specific components, such as RAM or storage. This extends the lifespan of the product and provides cost savings for the end user. Design teams should identify the components that are most likely to need upgrading and design the product with this in mind.</p><p><strong>Reusability:</strong> This strategy involves designing products with the ability to repurpose them after their initial use&ndash; for example, repurposing an old smartphone as a security camera. By designing products with reusability in mind, companies can reduce waste and possibly create new revenue streams by meeting two demands with one product. Design teams should identify potential secondary uses for the product and design it with these in mind.</p><p>By implementing these design-for-obsolescence strategies, electronic industry professionals can create more sustainable products that offer cost savings for end-users and reduce environmental impact. These strategies also align with ESG initiatives, making them a worthwhile investment for companies looking to improve their sustainability performance.</p><h2>Benefits of Partnering with a Supply Chain Expert</h2><p>Effectively managing component obsolescence requires expertise, resources, and time that many businesses may not have internally. A supply chain expert offering obsolescence management services can be beneficial. These services include optimizing inventory levels, improving quality and customer satisfaction, and providing business intelligence and decision-making support.</p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MDU1NDIyMjc3LTE2ODYwNTU0MjIyNzcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="Supply chain infographic" class="fr-fic fr-dii"><p>Optimizing inventory levels, reducing waste, and avoiding disruptions or delays in production or delivery can save costs and increase profits. For instance, companies can implement inventory optimization software that analyzes demand patterns and optimizes stock levels, reducing inventory carrying costs.</p><p>Ensuring product performance, reliability, and safety is critical for improving quality and customer satisfaction. Businesses can achieve this by implementing a quality management system that monitors and controls processes and activities affecting quality throughout the supply chain.</p><p>Providing business intelligence tools that track and record geographical and financial data about sales and help optimize supply chain strategy can enhance business intelligence and decision-making. The result can be an increase in sales and profitability for companies.</p><p>Getting help with obsolescence management from a supply chain expert can allow companies to focus on their core competencies, reduce costs, improve quality, enhance customer satisfaction, and grow their business. Companies can achieve their business objectives and manage component obsolescence effectively by partnering with a supply chain partner.</p><h2>Conclusion</h2><p>Component obsolescence is inevitable in today&rsquo;s dynamic electronics industry. However, it does not have to threaten product success if companies adopt a proactive obsolescence management strategy that begins at the design stage. Your business can mitigate obsolescence risks and maximize product value throughout its life cycle by following some best practices and partnering with a supply chain expert offering comprehensive solutions.</p><h4>Lifecycle Problems?</h4><p>Find Parts with MacroFab</p><a href="https://www.macrofab.com/blog/strategic-sourcing-production-planning" target="_blank">STRATEGIC SOURCING &amp; PRODUCTION PLANNING</a></section><section><br></section>

Even one obsolete component can challenge your design. 

Fifteen percent of electronic parts disappear from the market annually.  Are you ready if one of them is part of your design? 

Component Obsolescence Management Begins at Design

Electric machinery parts manufacturing in industry 

This guide delves into DFM's principles, implementation process, impacts, and challenges, aiming to provide readers with a comprehensive understanding of this integral concept.

Enhancing Industrial Processes through Design for Manufacturing: A Comprehensive Guide

<p id="isPasted">Component obsolescence is a major challenge for industries relying on electronics. Electronic parts go out of date fast - two to five years on average - and 15 percent disappear from the market annually. Outdated components harm product quality, reliability, and profitability, forcing several times more expensive due to limited supply, demand, counterfeit risks, or redesign. Thus, proactive obsolescence management, starting with product design, is crucial.</p><p>In this article, we will explore some of the reasons for component obsolescence, some of the best practices for managing it effectively, and some of the benefits of partnering with a supply chain expert who can help you mitigate obsolescence risks and maximize product value.</p><h2>Reasons for Component Obsolescence</h2><p>It is essential to understand the <a href="https://www.macrofab.com/blog/component-obsolescence/" target="_blank">factors contributing to component obsolescence</a>, which is a growing challenge for companies within the electronics industry.</p><p>One significant reason for component obsolescence is the rapid pace of technological innovation and development in the industry. This trend is shortening the life cycles of integrated circuits (ICs) by an average of 30 percent. A study by S&amp;P Global Market Intelligence revealed that over 50 percent of ICs have a lifespan shorter than five years.</p><p>Another contributing factor is the increasing consolidation and competition in the upstream supply chain through mergers and acquisitions (M&amp;A). This trend has led to more end-of-life (EOL) notifications and faster product life cycle changes. In fact, M&amp;A activity is currently affecting over 200 billion components worldwide, according to IHS Markit.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1685020987492-1685020987492.png" alt="Consumer demand electronics" class="fr-fic fr-dii"></p><p>Additionally, consumer demand for newer and smarter electronic products is driving more frequent upgrades and replacements of existing devices. For example, a recent survey by Accenture found that 47 percent of consumers plan to replace their smartphones every year or sooner.</p><p>Changes in government regulations and environmental standards also have a significant impact on component availability and compatibility. The Restriction of Hazardous Substances (RoHS) directive, for instance, prohibits the use of certain substances such as lead, mercury, or cadmium in electrical and electronic equipment sold in the European Union.</p><p>These factors pose significant challenges for companies that must ensure product designs are functional, reliable, compatible, compliant, and profitable throughout their intended life span. As an industry professional, it is crucial to keep up with these trends and their implications to make informed decisions about product design and component selection.</p><h2>Best Practices for Managing Component Obsolescence</h2><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1685020987613-1685020987613.png" alt="Best practices managing component obsolescence" class="fr-fic fr-dii"></p><p>To avoid or minimize the negative impact of component obsolescence on products and systems, it&rsquo;s essential to adopt an obsolescence management strategy during the product design phase. This involves incorporating best practices such as specifying components with long-term availability or multiple sources, leveraging production and order history to anticipate component turnover, communicating with end users to align design with customer expectations, maintaining regulatory compliance, and incorporating design-for-obsolescence strategies to ensure product longevity.</p><p>To reduce the risk of sourcing difficulties and price fluctuations due to limited supply or high demand, specify components that have long-term availability or have multiple sources for all necessary parts. For instance, choose to use components that are commonly found in other industries like automotive or aerospace, to ensure a stable supply chain. While this creates competition for their purchase, it also ensures they remain readily available, typically from multiple sources, as long as they remain in high demand. When you can&rsquo;t use these strategies, use best practices to <a href="https://www.macrofab.com/blog/reducing-single-source-component-risk" target="_blank">reduce single-source component risks</a>.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1685020987443-1685020987443.png" alt="Leverage order production history data" class="fr-fic fr-dii"></p><p>Leverage production and order history data to gain visibility into component turnover rates and identify parts that are at risk of becoming obsolete or slow-moving. Plan accordingly for inventory management or replacement strategies. Additionally, use data analytics to monitor the usage and performance of components and forecast their life expectancy to stay ahead of potential obsolescence. MacroFab&rsquo;s technology platform is ideally suited to provide this sort of analytical data.</p><p>Communicating with end-users to understand their needs and expectations regarding product longevity is crucial in ensuring that product design aligns with their requirements. By preventing premature obsolescence, unnecessary costs and dissatisfaction can be avoided.</p><p>Maintaining regulatory compliance requirements and forecasting their impact on parts in stock and production is essential in ensuring regulatory adherence, avoiding penalties or fines, and anticipating potential component availability or compatibility changes.</p><h2>Options to Consider at the Design Stage</h2><p>Design-for-obsolescence strategies such as modularization, standardization, upgradability, and reusability can enhance product flexibility, adaptability, and maintainability, ultimately extending product life span. Below are explanations of each strategy and how to use it:</p><p><strong>Modularization:</strong> This strategy involves designing products as a series of independent modules that can be easily replaced or upgraded. By doing so, end users can replace only the faulty or outdated module instead of buying a completely new device. This results in cost savings for the end user and reduces electronic waste. To implement modularization, design teams should identify the components that are most likely to become obsolete and design them as interchangeable modules.</p><p><strong>Standardization:</strong> This strategy involves using standard components and interfaces that are compatible with other products. For example, using USB ports for charging and data transfer instead of proprietary connectors. Standardization allows for greater interoperability between products, making it easier for end-users to replace or upgrade components. This strategy also makes it easier for manufacturers to source components and will ultimately reduce costs.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1685020987557-1685020987557.png" alt="Upgrade ram" class="fr-fic fr-dii"></p><p><strong>Upgradability:</strong> This strategy involves designing products with the ability to upgrade specific components, such as RAM or storage. This extends the lifespan of the product and provides cost savings for the end user. Design teams should identify the components that are most likely to need upgrading and design the product with this in mind.</p><p><strong>Reusability:</strong> This strategy involves designing products with the ability to repurpose them after their initial use&ndash; for example, repurposing an old smartphone as a security camera. By designing products with reusability in mind, companies can reduce waste and possibly create new revenue streams by meeting two demands with one product. Design teams should identify potential secondary uses for the product and design it with these in mind.</p><p>By implementing these design-for-obsolescence strategies, electronic industry professionals can create more sustainable products that offer cost savings for end-users and reduce environmental impact. These strategies also align with ESG initiatives, making them a worthwhile investment for companies looking to improve their sustainability performance.</p><h2>Benefits of Partnering with a Supply Chain Expert</h2><p>Effectively managing component obsolescence requires expertise, resources, and time that many businesses may not have internally. A supply chain expert offering obsolescence management services can be beneficial. These services include optimizing inventory levels, improving quality and customer satisfaction, and providing business intelligence and decision-making support.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1685020987654-1685020987654.png" alt="Supply chain infographic" class="fr-fic fr-dii"></p><p>Optimizing inventory levels, reducing waste, and avoiding disruptions or delays in production or delivery can save costs and increase profits. For instance, companies can implement inventory optimization software that analyzes demand patterns and optimizes stock levels, reducing inventory carrying costs.</p><p>Ensuring product performance, reliability, and safety is critical for improving quality and customer satisfaction. Businesses can achieve this by implementing a quality management system that monitors and controls processes and activities affecting quality throughout the supply chain.</p><p>Providing business intelligence tools that track and record geographical and financial data about sales and help optimize supply chain strategy can enhance business intelligence and decision-making. The result can be an increase in sales and profitability for companies.</p><p>Getting help with obsolescence management from a supply chain expert can allow companies to focus on their core competencies, reduce costs, improve quality, enhance customer satisfaction, and grow their business. Companies can achieve their business objectives and manage component obsolescence effectively by partnering with a supply chain partner.</p><h2>Conclusion</h2><p>Component obsolescence is inevitable in today&rsquo;s dynamic electronics industry. However, it does not have to threaten product success if companies adopt a proactive obsolescence management strategy that begins at the design stage. Your business can mitigate obsolescence risks and maximize product value throughout its life cycle by following some best practices and partnering with a supply chain expert offering comprehensive solutions.</p><p><br></p><section id="isPasted"><h4>Lifecycle Problems?</h4><p>Find Parts with MacroFab</p><a href="https://www.macrofab.com/blog/strategic-sourcing-production-planning" target="_blank"><strong>STRATEGIC SOURCING &amp; PRODUCTION PLANNING</strong></a></section><section><h4><br></h4><div data-aos="fade-up" data-aos-duration="750"><br></div></section><p><br></p>

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