Design-to-Cost

Design-to-Cost refers to a development approach in which the cost of a product is taken into account as a key objective already at the design stage. Alongside function and technical requirements, this approach considers from the outset how a component can be manufactured cost-effectively.

The aim is not simply to make a component as cheaply as possible. Rather, the objective is to strike a cost-effective balance between function, quality and cost. The scope for influence is particularly great in the early stages of development, when the geometry, material and manufacturing process can still be modified.

At MN Kaltformteile, components are assessed for manufacturability and cost-effective production even before production begins. In this context, adjustments to the geometry, alternative materials or a different manufacturing concept, for example, can open up further potential for optimisation.

Page Overview

Design-to-Cost for cold-formed parts
Design-to-Cost: Questions and answers

Design-to-Cost for cold-formed parts

When developing a component, a significant portion of the subsequent manufacturing costs is already influenced by design decisions. Geometry, tolerances, material, manufacturing process, production volume and required follow-up processes all play a part in determining how cost-effectively a component can later be produced in series.

For cold-formed parts, Design-to-Cost therefore begins as early as the component design stage. For example, it is possible to investigate which geometries can be produced directly through cold forming, which tolerances are actually functionally necessary, and whether subsequent machining operations can be reduced or avoided.

Material selection and material utilisation also play a role. At the same time, tooling costs and expected production volumes must be taken into account. Higher initial tooling costs can prove economically viable for appropriate production volumes due to short production times and high material utilisation.

MN Kaltformteile already takes such interrelationships into account as part of the technical manufacturability analysis. In this process, component geometry, material, tooling concept, manufacturing process and subsequent operations can be assessed together.

Existing components can also be examined for potential optimisation. For example, it can be assessed whether a component previously manufactured by machining can be produced entirely or partially by cold forming.

Design-to-Cost: Questions and answers

What does ‘Design-to-Cost’ mean?

Design-to-Cost refers to a development approach in which future product costs are taken into account right from the design stage. Technical requirements and cost-effectiveness are considered together.
What is the aim of Design-to-Cost?

The aim of Design-to-Cost is not to achieve the lowest possible component quality, but to find a cost-effective solution that meets all the necessary technical and quality requirements. To this end, costs are taken into account as a target parameter right from the development stage.
Why is it important to involve a manufacturing partner at an early stage?

The earlier a manufacturing partner is involved, the greater the possibilities there usually are for optimising geometry, materials and the manufacturing concept. If the design and materials have already been finalised, cost-effective manufacturing alternatives may only be considered to a limited extent.
What factors influence the manufacturing costs of a component?

Key influencing factors include, amongst others, the material, component geometry, tolerances, manufacturing processes, tooling costs, post-processing, testing requirements and production volume. Design-to-Cost does not consider these factors in isolation, but in conjunction with the component’s functional requirements.
How does MN Kaltformteile support Design-to-Cost?

MN Kaltformteile examines components as part of a technical manufacturability analysis to identify potential for technical and economic optimisation. This may involve assessing, amongst other things, geometry, material, tolerances, tooling concept, manufacturing process and any necessary subsequent operations. Even for existing turned or other machined parts, it is possible to assess whether switching to cold forming is technically and economically viable.

Design-to-Cost

Design-to-Cost for cold-formed parts

Design-to-Cost: Questions and answers

What does ‘Design-to-Cost’ mean?

What is the aim of Design-to-Cost?

Why is it important to involve a manufacturing partner at an early stage?

What factors influence the manufacturing costs of a component?

How does MN Kaltformteile support Design-to-Cost?