What are the most common DFM mistakes?
Non-uniform wall thickness on moulded parts, which causes sink and warp. Tolerances tighter than the process can hold, which turns into a scrap rate. Internal geometry that no tool can reach. Assemblies that require a third hand to build. Fastener choices that need a driver that will not fit the envelope.
None of these are exotic. They all come from the same root cause: the design was validated against a CAD model rather than against a process.
How do you build DFM into design instead of bolting it on?
Fix the process first. Before detailed modelling starts, decide how the part will be made and at what volume — injection moulding at 100,000 units is a different design problem to CNC machining at 200.
Then define the tolerance budget across the assembly, not part by part. A stack-up done at the end almost always produces at least one tolerance nobody can actually hold.
When should a DFM review happen?
At concept, at detailed design, and immediately before release. Three short reviews catch far more than one long one at the end, because by the end the cost of changing anything has already made everyone defensive.
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