Design decisions significantly impact machining complexity and cost. Common design pitfalls include:
Simplify Geometry
Avoid deep pockets, sharp corners, or thin walls requiring special tooling. Use fillets instead of right angles to reduce stress concentration.
Tolerance Rationalization
Non-critical features can use ±0.1mm tolerances instead of precision grades, cutting machining time.
Minimize Setups
Design for multi-axis machining in single setups when possible.
Standardize Features
Use uniform hole sizes/threads to minimize tool changes.
Early design consultation typically saves 15-30% in machining costs.