Keep it Simple to Make the Actual Production Easy

One of the most common mistakes even experienced design engineers and product developers make is to overly complicate their part designs. Consider breaking up single-piece, multi-faceted “super parts” into simpler components that can be bolted, glued, or screwed together. Unless required for functionality, avoid swept surfaces, as these generally require lengthy, more costly machining with a ball-nose milling cutter. Design parts with features that can be cut from one side wherever possible. This avoids multiple operations and possibly special fixturing, as well as having to use a more expensive five-axis machining center or 6-Axis capabilities.