Design for Aerospace Manufacturability

Redesign the Component for the Available CNC Process

1. 1
   Create a machine-capability table containing stock limits, axis travel, approved tools, cutter diameters, flute lengths, maximum depth, and workholding restrictions.
2. 2
   Audit every internal corner, slot, hole, and pocket for tool access. Mark any feature that cannot be reached by an assigned tool.
3. 3
   Compare every internal radius with the assigned cutter radius. Increase radii where the tool cannot create the original geometry.
4. 4
   Check minimum wall thickness, hole-to-edge distance, hole-to-hole spacing, and material remaining below pockets.
5. 5
   Identify how the stock will be held. Mark clamp, vise, fixture, or tab locations and the no-cut zones around them.
6. 6
   Determine how many setups the design requires. Revise the part to use one setup when practical and safe.
7. 7
   Check whether every critical feature can be measured with available calipers, gauges, pins, or fixtures.
8. 8
   Develop Concept A and Concept B. Each concept must preserve the required interfaces while improving manufacturability or reducing mass.
9. 9
   Estimate the effect of each concept on material removed, machining time, workholding, inspection, and risk.
10. 10
    Use a weighted decision matrix to select the preferred concept.
11. 11
    Complete the final DFM checklist and identify any accepted limitation that still requires teacher approval.