The global aerospace parts market is on an upward flight path due to increasing global air travel and the ongoing push to design and build more sustainable, fuel-efficient aircraft.
The market projects to grow to $1.3 trillion in value by 2031, and the companies focused on making all the necessary components – covering every square inch from the cockpit to the main fuselage to the tail fin – are growing rapidly as well. In the U.S. alone, there are approximately 1,800 companies involved in aerospace parts manufacturing, together generating approximately $250 billion in revenue collectively.
While the pieces and parts each company makes are unique to their expertise, the end goals for all are largely the same – to produce high-quality, compliant, safe, and functional parts profitably. The foundation for success lies in the design phase, particularly early on, when key decisions are made that will directly influence the overall manufacturability, cost efficiency, and compliance of the product. To help guide this delicate balancing act and make the best decisions possible, companies should commit to following the Design for Manufacturing and Assembly (DfMA) principles, which provide a core set of design tenets that can facilitate smoother production and deliver the desired results.
Impact of Design Decisions
Let’s probe a little deeper into the design decisions and factors that have the most influence on manufacturability, cost efficiency, quality, and compliance.
- Manufacturability
Thoughtful, well-considered designs cut down on complexity, drive efficiency, and minimize the need to use specialized skills or equipment that can slow processes down. Something as simple as using joints that snap fit together over screws can accelerate assembly and production time.
- Cost efficiency
From a cost standpoint, design decisions have a huge impact on going-forward production, encompassing everything from materials usage to tool and labor expenses. Companies involved in high-volume manufacturing in particular can reduce their costs by continuously improving their mass production techniques.
- Quality
Design also affects the quality of the end product in terms of safety and reliability. Every gram matters in aerospace and defense design which means the materials used matter. Lightweight designs improve fuel efficiency, and structural integrity is key for the extreme conditions these parts will go through, such as G-force or temperature variations.
- Compliance
Finally, designs must be established in adherence with prevailing regulatory standards, meaning any materials or production processes deployed must adhere to existing regulations and safety standards. As an example, building parts with lighter, recyclable materials supports the need to be more sustainable and fuel-efficient, while installing electrical insulation that meets requirements ensures safety.
DfMA: A Force Optimizer
DfMA has been widely adopted across many sectors, and is particularly concentrated in industries where efficiency, manufacturability, and assembly are mission critical. Beyond aerospace, DfMA is prevalent in areas such as automotive, electronics, consumer goods, and medical devices. The principles espoused give companies a solid decision-making framework by considering key factors like production constraints and capabilities and assessing whether the operation is fully aligned for success. Integrating DfMA principles early and often into the master design process can lead to streamlined production, reduced costs, and better product quality – three key catalysts for being able to check those aforementioned success boxes.
Implementation Trends & Considerations
In terms of how manufacturers adopt and integrate DfMA, larger enterprises like the Toyotas, Apples, and Medtronics of the world tend to establish their own dedicated DfMA teams because cost reduction and efficiency is so integral to their success. Smaller and medium-sized companies, on the other hand, tend to adopt DfMA on a more selective basis.
Irrespective of the type of component being built, and before drafting prototypes, it is critical for the R&D and design teams to collaborate with their manufacturing colleagues to find the right balance between innovation and manufacturability in the ultimate design. Following the tenets of DfMA early and often in the process helps ensure a more manufacturable design in terms of being assembly-friendly, cost-effective, and scalable. One recent survey, in fact, showed that companies deploying DfMA, on average, realize a 51% reduction in total parts used, a 37% decrease in overall costs, and 50% faster time to market. As an added bonus, establishing repeatable build processes can also check another one of those success boxes by enhancing compliance with industry standards.
Last, we cannot overemphasize the importance of documenting and keeping thorough records of everything you do and change, from first steps to implementation and then on an ongoing basis. Key methodologies should be documented and provide clear process steps around evaluating and improving designs to ensure repeatability. Thorough documentation also helps with scalability.
Tying It All Together with DfMA
Engineers and developers in the aerospace parts industry work to some of the highest standards in business and are tasked with designing products that strike the right balance between efficiency, cost, quality, and compliance. In our experience working with many on these very issues, we have seen firsthand how the tenets of DfMA keep companies focused on meeting this challenge by prioritizing four primary design and manufacturing goals:
- More efficient designs
Refining designs by reducing the number of parts needed and simplifying assembly makes for faster, less costly, and more scalable production. Additionally, the fewer parts involved the better in terms of minimizing defect potential, making maintenance easier and accelerating production cycles.
- Improved production time
Flagging and addressing any potential manufacturing challenges early in the design process is crucial to avoid delays and keep projects running to schedule.
- Repeatable template for success
Circling back to the need to document anything and everything – keeping a comprehensive record will help ensure that design improvements can be applied to other projects going forward, generate consistent results, and cut back on the need to duplicate efforts.
- Balancing compliance and efficiency
Following DfMA principles ensures that designs are developed to meet stringent aerospace industry standards while also keeping costs down and efficiency up.
Strategic Imperative
Embedding DfMA principles into aerospace parts production is more than just a method or initiative aimed at achieving efficiency and cost savings. By focusing on manufacturability in the earliest stages of design, particularly in today’s competitive environment, companies can simplify production, cut out complexity, and meet strict standards and guidelines without sacrificing quality or innovation. The benefits extend beyond individual projects, too, as they can instill a culture of continuous improvement, scalability, and long-term growth and success. As the global aerospace parts market continues to grow, those prioritizing DfMA will be in a strong position to deliver this critical componentry efficiently, safely, and sustainably.
