Production-Ready Hardware Design
Engineered for Manufacturing from Day One
We help hardware companies move from concept to tooling-ready products — with wall thickness strategy, assembly planning, and manufacturing constraints engineered into every design decision.
THE PROBLEM
Most Products Fail Between Prototype and Production
The majority of costly redesigns happen not because of aesthetics — but because:
Wall thickness was not engineered correctly
Assembly planning was an afterthought
Tooling constraints were ignored
Tolerances were not controlled early
Manufacturing economics were not considered
These problems only surface once tooling money is committed — when change becomes expensive.
We prevent that.
WHAT WE DO
Production-Ready Hardware Development
3D DFM Pty Ltd specializes in manufacturing-ready product design for hardware companies preparing for tooling and production.
We engineer products to be:
Injection molding ready
Structurally sound
Assembly-efficient
Cost-aware
Tooling-conscious
Scalable for manufacturing
This is not concept styling.
This is production-bound engineering.
OUR APPROACH
How We Move Your Product Toward Tooling
1. Architecture & Assembly Strategy
Define product structure, part breakdown, fastening logic, and serviceability before geometry is finalized.
2. Wall Thickness & Manufacturing Engineering
Develop injection molding-ready geometry with controlled transitions, rib strategy, and structural logic.
3. Production-Ready CAD Delivery
Deliver detailed 3D CAD prepared for tooling discussions, supplier engagement, and early production validation.
The goal is simple:
Reduce tooling risk. Shorten development cycles. Avoid expensive redesign.
WHO WE WORK WITH
We work with:
Hardware startups preparing for production
Consumer product teams launching injection molded products
Medical and industrial device companies
IoT and enclosure-based product developers
Engineering teams needing production-bound expertise
If your product is moving toward tooling, we should be involved before capital is committed.
WHY 3D DFM
With 30 years of hands-on mechanical and Design for Manufacturing experience, 3D DFM brings factory-floor knowledge into early-stage hardware design.
Experience includes:
Injection mold tooling exposure
CNC machining and production processes
Sheet metal fabrication
Multi-part mechanical assemblies
Manufacturing economics integration
We design parts the way a factory must build them — repeatedly, predictably, and profitably.
OUTCOME
What You Gain
Fewer tooling revisions
Reduced development delays
Predictable assembly processes
Controlled production cost
Confidence before committing to tooling
Production-ready design is not an add-on.
It must be engineered from the beginning.
Preparing to Move Toward Tooling?
If you are transitioning from prototype to production and want to reduce manufacturing risk before committing significant capital, the next step is a structured discussion.
Engineering Leadership Behind 3D DFM Pty Ltd
3D DFM is led by Mechanical Engineer Ben Nel, bringing nearly 30 years of hands-on Design for Manufacturing experience across injection molding, CNC machining, sheet metal fabrication, and multi-part mechanical systems.
Unlike design studios focused primarily on aesthetics, 3D DFM integrates manufacturing constraints, tooling logic, and cost economics into every design decision from the first sketch.
This factory-informed perspective ensures products are engineered not just to look right — but to be built reliably, repeatedly, and profitably.
Our work spans:
Complex mechanical assemblies
Medical and industrial hardware
Consumer products preparing for tooling
Every project is approached with one goal:
Engineering it correctly before production begins.
“If a factory cannot build it repeatedly, predictably, and profitably — the design is not finished.”
Client Testimonials
Medical Device: Basil Srouji – Israel
“Ben was incredibly professional throughout the entire design process. He kept us informed and was eager to accept our reviews and incorporate these into the design. His depth of knowledge and understanding of plastic manufacturing resulted in a design that was completed promptly and without issue. I had a tremendously positive experience working with Ben and can 100% recommend his work to others.”
Hand Tool Development: iFixit – Brett Hartt – USA
“Ben and team did a good job of showing progress and designing to the final desired outcome. Ben was very good at showing status reports and progress made.”
Medical Sanitizing Unit: Reggie Jean-Brice – USA
“Ben was incredible to work with, super responsive, efficient work. We want to bring him on another project very soon. Highly recommended”
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