Production-Proven Product Design & DFM Case Studies
3DDFM helps companies move physical products from concept and prototype toward tooling, fabrication and reliable production.
The case studies below focus on real products that progressed into commercial manufacturing, rather than concepts or presentation renders alone.
They demonstrate experience in:
injection molded product design
electronic enclosure design
sheet metal product engineering
Design for Manufacturing (DFM)
Design for Assembly (DFA)
mechanism development
injection mold tooling
FEA
manufacturing drawings and production documentation
first-off-tool evaluation and production support
These case studies include selected work completed by 3DDFM and founder Ben Nel during more than 30 years of product development and manufacturing experience.
Manufacturing Experience at a Glance
- 65+ electrical products developed for one long-term manufacturing client
- 100,000+ units manufactured for selected high-volume injection molded products
- 5,000+ units manufactured for a production electronic enclosure
- Complete injection mold tooling designed for a commercial electronic product
- 20+ sheet metal and mechanical products developed for an access-control manufacturer
- Production products still manufactured and supplied to international markets
Injection Molding & High-Volume Electrical Products
Lesco Manufacturing
Product Design from Concept to High-Volume Production
Over a working relationship spanning approximately 1996 to 2017, Ben Nel developed approximately 65 products for Lesco Manufacturing, including injection molded electrical products, adapters, switches and related assemblies.
The work extended beyond CAD modelling and included product development from concept through production.
Engineering Scope
aesthetic and product design
injection molded plastic part design
injection molding DFM
progressive-die component DFM
mechanical switch and sliding mechanisms
packaging of small components into complex assemblies
Design for Assembly
error-proof assembly features
design around applicable electrical product requirements
interaction with tooling manufacturers
first-off-tool evaluation and design changes
assembly jig development
production testing jig development
production support
Injection mold and progressive-die tooling was designed and manufactured by specialist Chinese tooling suppliers, while plastic production, assembly and testing took place in South Africa.
Production Proof
Selected products were manufactured in quantities exceeding:
100,000 Units
Two examples from this long-term product-development relationship are the 4-Way 232 Electrical Adaptor, developed in 2006, and the Cover Strip Range, developed in 2015.
The Cover Strip Range was developed from the client’s product direction into production-ready injection molded products.
View High-Volume Injection Molding Case Study
Injection Molding Design Service
Electronic Enclosure & Injection Mold Tool Design
Romulus Energy — AS1X MeterModem
Production Electronic Housing Designed with Its Injection Mold Tooling
The AS1X MeterModem project demonstrates the connection between electronic enclosure design, injection molding DFM and injection mold tool design.
Unlike projects where 3DDFM provides only product CAD for an external toolmaker, this project included development of both the production enclosure and the complete injection mold tooling required to manufacture it.
Engineering Scope
product design
aesthetic design
electronic enclosure development
internal component packaging
injection molding DFM
production CAD
complete injection mold tool design
Production Proof
The product entered commercial production in approximately 2018.
5,000+ Units Manufactured
This project provides direct production evidence of experience extending from the external electronic housing through to the tooling used to manufacture the molded components.
View Electronic Enclosure & Mold Design Case Study
Electronic Enclosure Design Service
Sheet Metal Product Engineering & DFM
Turnstar Systems
Production Sheet Metal Products, Mechanisms and Manufacturing Documentation
Between approximately 2016 and 2021, Ben Nel and the 3DDFM team worked on approximately 20 products for Turnstar Systems.
The work involved significantly more than creating sheet metal geometry. Projects required the complete development of fabricated products and mechanical systems around real manufacturing, welding, assembly, structural, transport and installation requirements.
Engineering Scope
aesthetic product design
sheet metal DFM
mild steel and stainless steel product development
mechanism design
structural engineering
weight optimisation
transport optimisation
site-assembly optimisation
FEA of critical structures and components
assembly jig design
welding jig design
complete manufacturing drawing packs
BOMs
DXF manufacturing profiles
welding drawings
production CAD
marketing renders
Triton Full Height Curved — 2020
The Triton Full Height Curved project involved a major redesign of an existing commercial product.
Engineering work included sheet metal DFM, structural and mechanism development, FEA and complete manufacturing documentation.
Fusion Full Height Octagonal — 2020
The Fusion Full Height Octagonal was developed as a new commercial product design.
The project included product development, fabrication engineering, structural analysis, mechanisms, DFM and production documentation.
Production Proof
Both selected products:
have been manufactured in quantities exceeding 20 units
remain in commercial production
are offered to international markets
Manufacturing documentation for these projects was developed by Ben Nel and Armandt as part of the engineering work.
View Sheet Metal Product Engineering Case Study
What Do These Case Studies Demonstrate?
Have you designed injection molded products that reached mass production?
Yes. Selected electrical products developed through the Lesco relationship were manufactured in quantities exceeding 100,000 units.
The work included injection molding DFM, mechanical assemblies, progressive-die components, Design for Assembly, tooling interaction and first-off-tool changes.
See the Injection Molding Case Stud
Have you designed a production electronic enclosure around real electronics?
Yes. The Romulus AS1X MeterModem was developed as a commercial electronic product and more than 5,000 units were manufactured.
The work included electronic enclosure design, internal component packaging, injection molding DFM and complete injection mold tool design.
See the Electronic Enclosure Case Study
Do you have experience designing the injection mold itself?
Yes.
For the Romulus AS1X project, the engineering work included the complete injection mold tool design, not only the plastic product geometry.
This tooling experience provides a practical understanding of how molded product geometry affects mold construction and production.
See the Electronic Enclosure & Mold Design Case Study
Have you designed sheet metal products that are still being manufactured?
Yes.
Selected Turnstar sheet metal products developed in 2020 remain in commercial manufacture and are offered to international markets.
The work included sheet metal DFM, mechanisms, FEA, fabrication engineering and complete manufacturing documentation.
See the Sheet Metal Product Engineering Case Study
Can you take a product from concept through manufacturing?
3DDFM’s experience includes projects spanning:
Concept → Product Design → DFM → Prototype → Tooling/Fabrication → First-Off Parts → Production
The exact scope depends on the product and manufacturing process, but our focus is always on developing physical products around how they will eventually be manufactured, assembled and used.
Design for Manufacturing Consulting
Find the Relevant Engineering Service
Injection Molding Design
For plastic products moving toward injection mold tooling, including wall thickness, draft, ribs, bosses, undercuts, assembly features and tooling considerations.
Electronic Enclosure Design
For PCB-based products requiring internal packaging, connector and display integration, fastening, assembly and a production-ready housing.
Sheet Metal Design
For fabricated products requiring bending, welding, structural engineering, mechanisms, DXFs and manufacturing documentation.
Design for Manufacturing Consulting
For existing products and CAD that need an independent manufacturing review before committing to tooling, fabrication or production.
Need Proof Relevant to Your Product?
If you are evaluating 3DDFM for a manufacturing-focused product development project, start with the case study closest to your manufacturing process.
For new projects, provide information about your product, current development stage, intended production process and manufacturing goals.