Complete Design-to-Manufacturing Support for Custom Components and Parts

What Is Design-to-Manufacturing Support?

Design-to-manufacturing (DTM) support is a seamless, systematic process guiding your product from initial CAD drawings to the final manufactured components. Key advantages include streamlined communication, quicker iterative cycles, and thorough optimization for manufacturability, functionality, and cost-effectiveness.

Key stages include:

• Design optimization (DFM - Design for Manufacturability, DFA - Design for Assembly)

• Material selection based on ASTM, ISO, and other industry standards

• Prototype development via CNC machining, die casting, or additive manufacturing

• Iterative validation with precise tolerance verification

• Tooling and fixture design and validation

• Mass production, in-line inspection, and detailed post-processing

Why Choose an Integrated DTM Partner?

Design and Engineering Services

Our in-house engineering support includes comprehensive evaluation services:

• 2D to 3D CAD conversion and validation per ISO 10303 (STEP) standards

• DFM analysis: optimization of wall thicknesses (minimum recommended: aluminum ≥ 1.5 mm, zinc ≥ 0.8 mm), draft angles (standard 1–3°), and tolerance stack-ups (±0.05 mm standard)

• Finite Element Analysis (FEA) compliant with ISO 9001 and ASME standards to assess stress (up to 400 MPa), thermal distribution, and vibration resistance

• ASTM-based material recommendations, ensuring compliance with required tensile strength, thermal conductivity, corrosion resistance, and cost-efficiency parameters

For example, during a custom sensor enclosure project, we achieved a 12% weight reduction by optimizing rib geometry and switching from A360 aluminum (tensile strength ~317 MPa) to AlSi12 (tensile strength ~240 MPa, superior castability), meeting the client’s performance and budget goals.

Rapid Prototyping and Pre-Production Validation

We utilize advanced prototyping methods:

• SLA/SLS 3D printing technologies with dimensional accuracy of ±0.1–0.3 mm, ideal for initial visual validation

• CNC machining prototypes capable of achieving tolerances down to ±0.005 mm, delivered within 3–7 business days

• Soft tooling options (P20 steel) suitable for batch sizes of 50–500 units, ready within 10–20 days

• Urethane casting for limited pre-production testing runs (typically under 100 units), achieving dimensional accuracy of ±0.25 mm

These prototyping services enable rapid feedback and design iterations, significantly reducing overall development lead times.

Tooling Design and Production Readiness

Neway offers robust tooling solutions, ensuring readiness for high-volume manufacturing:

• Die-cast tooling made from P20 and H13 steel, capable of 300,000 to 500,000 production cycles

• Multi-cavity molds (2–8 cavities standard), reducing per-unit cycle times (typically 20–60 seconds per shot)

• Modular tooling systems facilitating rapid adjustments for product variations within days

• Mold-flow analysis compliant with ASTM D6204 for die-cast filling patterns, venting optimization, and minimizing porosity below industry-standard (≤ 0.5%)

Material and Process Specifications

Selecting optimal materials and processes according to ASTM and ISO standards ensures performance and cost control:

Common Materials

• Aluminum Alloys:

  • A380 aluminum (ASTM B85, tensile strength ~324 MPa, thermal conductivity ~96 W/m·K)

  • AC8A aluminum (JIS H5302, tensile strength ~320 MPa, excellent corrosion resistance)

  • AC4C aluminum (JIS H5302, tensile strength ~275 MPa, thermal conductivity ~120 W/m·K)

• Zinc Alloys:

  • Zamak 3 (ASTM B240, tensile strength ~268 MPa, dimensional precision ±0.05 mm)

  • ZA-8 (ASTM B86, tensile strength ~374 MPa, good bearing properties)

• Copper Alloys:

  • Brass 360 (ASTM B16, tensile strength ~345 MPa, corrosion-resistant)

  • C18200 copper (ASTM B441, electrical conductivity ~80% IACS, ideal for electrical components)

Production Processes

• Die casting: capable of high-volume production (50,000–1,000,000+ parts/year), tolerances ±0.1 mm standard

• CNC machining: precision features achievable to ±0.005 mm, surface finishes down to Ra 0.8 µm

• Post-processing: anodizing thickness per MIL-A-8625 Type II (10–25 µm), powder coating per ASTM D3451 (60–100 µm thickness)

• Assembly services: meeting IPC-A-610 and ISO 9001 standards, comprehensive QA and documentation support

Conclusion

Effective custom component development requires integrated engineering, precise validation, and scalable manufacturing. Neway’s comprehensive design-to-manufacturing support ensures products achieve industry-leading standards in quality, precision, and efficiency from the outset.

Partner with Neway to accelerate your component development journey, from concept through mass production, with consistent reliability and industry-leading performance.

FAQs

1. What CAD formats does Neway accept for custom component manufacturing?

2. How fast can CNC-machined prototypes be produced at Neway?

3. Can Neway’s tooling accommodate large-scale production runs exceeding 100,000 units per year?

4. What quality control and inspection standards does Neway follow?

5. Does Neway provide comprehensive documentation, including compliance certificates, for production batches?