Updated: Jul 6, 2021
Here are 5 quick ways to reduce cost (and increase profits) in your device:
Simplify assembly processes
Introduce fixtures to speed up assembly
Plan for assembly automation
Design for snap catches instead of screws or adhesive
Automated adhesive dispensing (when adhesive can’t be avoided)
Common parts/screws to simplify decision making
Design with assembly in mind (!) surprising, but this one gets skipped frequently
Reduce materials cost
Select lower-cost materials (tradeoff is quality)
Design smaller parts (to reduce raw material cost)
Replace custom components with off-the-shelf components
Reduce the weight of material
Increase tooling/capital expense
Multi-cavity tools drastically reduce part cost
Batch processing reduces unit cost
Add manufacturing processes in-house that are typically outsourced
Add automation/robots. All the robots.
Remove non-critical functionality
Remove charging capability – design for user-replaceable battery
Eliminate display; put display functionality on smartphone
Remove buttons; put button functionality on smartphone
Eliminate removable power cord, design integrated power cord.
Is soft-touch finish required? Can painted soft-touch replace insert-mold?
Can a color LCD be replaced by an e-ink display?
Do you really need IP-67 waterproof rating?
Reduce packaging costs
Shrink packaging size
Redesign for off-the-shelf packaging
Simplify packaging design, change user experience
Use lower-cost processes that match order volumes
Can you think of any that I missed?
I’m an expert in design of injection molded parts and complex mechanical devices. Do you need help? I’d love to help design/engineer your next project.
Make it an excellent week!
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