Design for Manufacturability

Posted by Steve Rowe on

How early design decisions impact cost, lead time, and yield
I’m expanding on my very first blogpost from 2020. Today, we’re discussing the concept of Design for Manufacturability (DFM) in more detail. In precision optics, performance often takes center stage during the design phase. But how an optic is designed, and how manufacturable it is, is just as important as how it performs on paper. Having more insight on DFM helps bridge the gap between concept and production, ensuring that optical components can be manufactured efficiently, consistently, and at scale without sacrificing performance. 

What Design for Manufacturability Really Means
Design for Manufacturability in precision optics is the practice of considering manufacturing constraints early in the design process. This includes material selection, geometry, tolerances, surface requirements, and coatings. When these factors are aligned with proven manufacturing processes, production becomes more predictable and cost-effective. Now, how can an engineer or procurement professional know about manufacturing constraints? Well, that’s the whole point of this blog.  

Early design decisions shape cost
Cost in optical manufacturing is often determined long before the first part is produced. Extremely tight tolerances, complex geometries, or uncommon materials can dramatically increase fabrication and inspection time. 

By engaging manufacturing experts early, designers can often relax non-critical tolerances, simplify features, or select alternative materials that achieve the same optical performance at a lower cost. I’ve discussed overspecifications before, and I understand that you want the best possible optics. However, small adjustments at the design stage can lead to significant savings over the life of a program. For procurement teams sourcing precision optics, design decisions made early in a program often determine whether a project stays on budget and on schedule or becomes a recurring challenge. 

Lead time is influenced at the drawing stage
Lead time is another area heavily impacted by early design choices. Custom tooling, specialized polishing processes, or limited material availability can add weeks or months to a project timeline. I’ve had customers design a system based on a legacy specialty glass only to find out it would be months before that material is readily available.  

Designs that align with standard manufacturing processes and utilize readily available materials move through production more efficiently. Clear drawings, realistic tolerances, and well-defined inspection criteria also reduce back-and-forth during fabrication, keeping schedules on track. 

Improving Yield Through Smarter Design
Yield—the percentage of parts that meet specifications on the first pass is a critical metric in precision optics. Designs that push manufacturing limits increase the likelihood of scrap or rework. 

DFM helps improve yield by accounting for natural process variation and focusing on tight tolerances only where they truly matter. When critical optical surfaces and features are prioritized, manufacturers can consistently deliver high-quality parts while minimizing waste. 

Collaboration is key
When optical designers, engineers, and manufacturers work together early, potential challenges can be identified and addressed before they become costly problems. This collaborative approach often leads to design refinements that improve manufacturability without compromising system performance. 

Conclusion
Design for Manufacturability is not about limiting innovation—it’s about enabling it. By considering manufacturability from the outset, optical designs can achieve better cost control, shorter lead times, and higher yields. The result is a smoother transition from design to production and optical components that deliver performance reliably in the real world. 

Share this post

← Older Post

Quality Optics from a Trusted Supplier

American Owned & Operated

Committed to supporting American industry and ensuring the highest-quality production standards.

Military & Defense Supplier

Esco Optics proudly manufactures precision optics for all branches of the armed forces land, sea, air and space.

ITAR Registered & Compliant

Esco manufactures compliant ITAR optics for all of its customers with the strictest confidentiality.

Making Light Work

Dedicated to fostering connections, collaboration, and innovation across the optics manufacturing industry.