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Design for Manufacturing using the Design to Unit Production Cost (DTUPC) Model


Our organization is often initially selected as a second source on existing programs to offer an alternative approach which is nimble, cost effective and explicitly reliant on unconventional and unique manufacturing techniques to succeed where others have failed.   These programs often involve manufacturing advanced composite structures within programs which are currently operating outside the expected cost structure.  More often than not our role as second source is quickly transitioned to primary source vendor once the benefits of our manufacturing principals have been applied to the program.  We have successfully applied the Design to Unit Production Cost method to Naval Systems, Unmanned Aircraft and extremely complex composite laminates.


Typical DFM Approaches

Design for manufacturing improvements can be realized using the following principals when properly applied:

  • Net Molding: Eliminating the need for post molding operations and CNC trimming will greatly reduce cost per unit.  We have successfully net molded IML, OML, holes and slots into complex composite structures simultaneously.

  • Alternate Materials:  Eliminating problematic and overpriced supply chain sources with equivalent materials backed with existing b-basis allowables can be a simple method to reducing lead times and cost.

  • Unconventional Processing:  We have developed several molding and infusion processes for extremely large structures which leverage the diversity of our composites knowledge.  These practices often eliminate scrap, reduce labor touch times and improve yields.

  • BOM Reduction:  Primarily in the Unmanned Systems market there is a significant amount of post processing and secondary bonding of brackets, hinges, and 3D printed components to completed composite structures.  Our team members have developed unique processes which allow for the in-mold placement of these structures, including 3D printed elements, and the subsequent co-curing during lamination.  The resulting assemblies require little or no post processing.

Contact Engineering Today

Contact our Engineering Team today to discuss how we can put our DFM experience to work on your composites program!