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Design for X

Boston Engineering Focus DFX Areas

The “X” represents various targets like manufacturability, reliability, usability, etc. The below are X’s where Boston Engineering knows how to maximize the Impact.

Start Your DFX Journey

Design with Purpose

At Boston Engineering, DFX is a core part of our product development process. We focus on several key DFX areas that align with our expertise:

DFX is key to our record of bringing successful products to market across industries. By taking a holistic DFX approach, companies can develop differentiated products that exceed customer expectations, meet business goals, and provide competitive advantage.

The upfront DFX investment pays dividends across the entire product lifecycle.

 

Design for Manufacturability (DFM)

 

DFM focuses on optimizing the manufacturing process by designing components and products that can be reliably produced within cost, quality, and time constraints.

 

Our DFM approach includes:

  • Simplifying designs for easier production with less process steps
  • Utilizing common parts and materials when possible
  • Designing parts for optimum manufacturability on available processes (injection molding, machining, etc.)
  • Minimizing need for complex tooling and fixtures
  • Eliminating secondary operations like drilling, tapping, etc. when feasible
  • Considering capabilities of manufacturing partners early in the design process

 

Design for Assembly (DFA)

DFA deals with optimizing the product assembly process.

Our DFA expertise includes:

  • Reducing overall part count in assemblies
  • Designing parts that self-locate and self-fasten when possible
  • Minimizing reorientation of parts during assembly
  • Eliminating adjustments and calibrations in assembly when possible
  • Reducing skilled labor requirements in assembly
  • Optimizing assembly steps, sequences, and handling

 

Design for Cost (DFC)

DFC focuses on meeting cost targets through design optimization.

Our DFC capabilities include:

  • Estimating manufacturing costs early through detailed production analysis
  • Tracking cost breakdowns of materials, labor, tooling, etc.
  • Targeting high cost drivers for reduction or elimination
  • Utilizing common parts and processes to maximize volumes
  • Simplifying components for easier production
  • Evaluating alternative materials, processes, sourcing options

 

Design for Testability (DFT)

We design products with testing in mind to verify performance and reduce cost of testing.

DFT tactics include:

  • Incorporating test points and interfaces for electrical/electronic modules
  • Designing mechanical assemblies for easy fixturing and access during testing
  • Defining critical test parameters and tolerances upfront
  • Utilizing modeling and simulation to enable virtual testing when possible
  • Specifying standardized tests using industry best practices
  • Designing products for automated testing when applicable

 

Design for Reliability (DFR)

To meet reliability goals, we utilize techniques like:

  • Selecting components with sufficient quality and ratings for the application
  • Performing derating, FMEA, thermal analysis, etc. to ensure robust design
  • Adding redundancy into the design where necessary
  • Specifying materials, surface finishes, etc. suitable for the operating environment
  • Running HALT/HASS testing to uncover failure modes and mechanisms
  • Reviewing legacy field performance data to inform reliability improvements

Beep Device Integration

 

Design for Serviceability/Maintainability (DFS)

We design products for service and maintenance throughout their lifecycle.

DFS techniques include:

  • Designing modules/components for easy removal/replacement
  • Incorporating self-diagnostics capabilities and error logging/reporting
  • Specifying quick-access panels and fasteners for common repair tasks
  • Defining preventative maintenance schedules to maximize uptime
  • Minimizing service parts inventory through commonality and modularity
  • Creating detailed service documentation and training for field technicians

workforce sustainment

 

Design for Usability (DFU)

DFU focuses on optimizing the user experience.

Our DFU expertise includes:

  • User research to understand needs, workflows, and environments
  • Prototyping interfaces for user feedback
  • Applying human factors standards appropriate for the product
  • Iterating designs based on usability testing
  • Validating designs through final user testing

 

 

Design for Modularity (DFMo)

DFMo involves creating interchangeable components that enable product flexibility.

Our DFMo capabilities include:

  • Identifying common subsystems, modules and interfaces
  • Defining modular architectures balancing flexibility and cost
  • Utilizing common components and production processes
  • Designing interfaces enabling field upgrades and enhancements

 

Design for X Case Studies

DFX is at its most impactful when it is used as part of a business’s overall strategy. See where DFX can have its greatest impact.

Wind Profile Generator Accelerates Small UAS Testing and Training

The system provides controlled, monitored, uniform, and laminar air flow.
Learn how our design created a consistent testing enviornment

Snowboard Innovator Sharpens its Competitive Edge with Redesigns

With a new ski season approaching, the brand faced performance challenges
Learn how redesign created new opportunities

Handheld Tool Recharge Improves Usability and Performance

Boston Engineering developed a field oriented control design to replace the product’s existing motor control capabilities.
See how design can improve business performance

Design for X from Boston Engineering

Innovative Product Development

Saving Lives with Accelerated Development of Mechanical Ventilators

Saving Lives with Accelerated Development of Mechanical Ventilators

CASE STUDY
Improving Public Health with Affordable Disease Tests

Improving Public Health with Affordable Disease Tests

CASE STUDY
Commercial Exoskeleton That Protect The Lives of U.S. Soldiers in Combat

Commercial Exoskeleton That Protect The Lives of U.S. Soldiers in Combat

CASE STUDY
A Robotic Fish That Defends Our Homeland Against Deadly Attacks

A Robotic Fish That Defends Our Homeland Against Deadly Attacks

CASE STUDY
Technology that Disrupts the Rapid Disease-Testing Market

Technology that Disrupts the Rapid Disease-Testing Market

CASE STUDY
Smithsonian Astrophysical Observatory Advances Deep Space Research

Smithsonian Astrophysical Observatory Advances Deep Space Research

CASE STUDY
Snowboard Innovator Sharpens its Competitive Edge with Redesigns

Snowboard Innovator Sharpens its Competitive Edge with Redesigns

CASE STUDY
Handheld Tool Recharge Improves Usability and Performance

Handheld Tool Recharge Improves Usability and Performance

CASE STUDY
Robotics Start-up Yields High Growth in the Agricultural Industry

Robotics Start-up Yields High Growth in the Agricultural Industry

CASE STUDY
Iconic Brand Reboots with High-Tech Product, Taps Growth Markets

Iconic Brand Reboots with High-Tech Product, Taps Growth Markets

CASE STUDY

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