Product Design for Manufacture and Assembly: 3rd Edition (Hardback) book cover

Product Design for Manufacture and Assembly

3rd Edition

By Geoffrey Boothroyd, Peter Dewhurst, Winston A. Knight

CRC Press

712 pages | 497 B/W Illus.

Purchasing Options:$ = USD
Hardback: 9781420089271
pub: 2010-12-08
eBook (VitalSource) : 9780429142963
pub: 2010-12-08
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Hailed as a groundbreaking and important textbook upon its initial publication, the latest iteration of Product Design for Manufacture and Assembly does not rest on those laurels. In addition to the expected updating of data in all chapters, this third edition has been revised to provide a top-notch textbook for university-level courses in product design and manufacturing design. The authors have added a comprehensive set of problems and student assignments to each chapter, making the new edition substantially more useful.

See what’s in the Third Edition:

  • Updated case studies on the application of DFMA techniques
  • Extended versions of the classification schemes of the features of products that influence the difficulty of handling and insertion for manual, high-speed automatic, and robot assembly
  • Discussions of changes in the industry such as increased emphasis on the use of surface mount devices
  • New data on basic manufacturing processes
  • Coverage of powder injection molding

Recognized as international experts on the re-engineering of electro-mechanical products, the methods and guidelines developed by Boothroyd, Dewhurst, and Knight have been documented to provide significant savings in the product development process. Often attributed with creating a revolution in product design, the authors have been working in product design manufacture and assembly for more than 25 years. Based on theory yet highly practical, their text defines the factors that influence the ease of assembly and manufacture of products for a wide range of the basic processes used in industry. It demonstrates how to develop competitive products that are simpler in configuration and easier to manufacture with reduced overall costs.


"If you are a manufacturer needing to reduce the cost of your products in a highly competitive international market, go out and buy this book. If you are a manufacturing student looking to learn something that will increase your value to potential employers, go out and buy this book. If you are a design engineer who wants to make for a penny, what a fool can make for two then go out and buy this book . . . it is a practical book, it works spectacularly well in the real world."

—Ernie Appleton, in Industrial Robot, April 2008

Praise for the First Edition

"…presents an excellent analysis of the evaluation methods of cost and performance of manufacturing and assembling technologies … an excellent reference."

European Journal of Mechanical Engineering, 1995

Table of Contents


What Is Design for Manufacture and Assembly?


Implementation of Design for Assembly

Design for Manufacture

Producibility Guidelines

How Does DFMA Work?

Falsely Claimed Reasons for Not Implementing DFMA

What are the Advantages of Applying DFMA during Product Design?

Overall Impact of DFMA on U.S. Industry

Selection of Materials and Processes

General Requirements for Early Materials and Process Selection

Selection of Manufacturing Processes

Process Capabilities

Selection of Materials

Primary Process/Material Selection

Systematic Selection of Processes and Materials


Product Design for Manual Assembly

General Design Guidelines for Manual Assembly

Development of the Systematic DFA Methodology

Assembly Efficiency

Classification Systems

Effect of Part Symmetry on Handling Time

Effect of Part Thickness and Size on Handling Time

Effect of Weight on Handling Time

Parts Requiring Two Hands for Manipulation

Effects of Combinations of Factors

Effect of Symmetry for Parts that Severely Nest or Tangle and May Require Tweezers for Grasping and Manipulation

Effect of Chamfer Design on Insertion Operations

Estimation of Insertion Time

Avoiding Jams during Assembly

Reducing Disc-Assembly Problems

Effects of Obstructed Access and Restricted Vision on Insertion of Threaded Fasteners of Various Designs

Effects of Obstructed Access and Restricted Vision on Pop-Riveting Operations

Effects of Holding Down

Manual Assembly Database and Design Data Sheets

Application of the DFA Methodology

Further Design Guidelines

Large Assemblies

Types of Manual Assembly Methods

Effect of Assembly Layout on Acquisition Times

Assembly Quality

Applying Learning Curves to the DFA Times

Electrical Connections and Wire Harness Assembly

Wire or Cable Harness Assembly

Types of Electrical Connections

Types of Wires and Cables

Preparation and Assembly Times

Analysis Method

Design for High-Speed Automatic Assembly and Robot Assembly

Design of Parts for High-Speed Feeding and Orienting


Additional Feeding Difficulties

High-Speed Automatic Insertion


Analysis of an Assembly

General Rules for Product Design for Automation

Design of Parts for Feeding and Orienting

Summary of Design Rules for High-Speed Automatic Assembly

Product Design for Robot Assembly

Printed Circuit Board Design for Manufacture and Assembly

Design Sequence for Printed Circuit Boards

Types of Printed Circuit Boards

Bare Board Manufacture


Assembly of Printed Circuit Boards

Estimation of PCB Assembly Costs

Case Studies in PCB Assembly

Glossary of Terms

Design for Machining

Machining Using Single-Point Cutting Tools

Machining Using Multipoint Tools

Machining Using Abrasive Wheels


Choice of Work Material

Shape of Work Material

Machining Basic Component Shapes

Assembly of Components

Accuracy and Surface Finish

Summary of Design Guidelines

Cost Estimating for Machined Components

Design for Injection Molding

Injection Molding Materials

The Molding Cycle

Injection Molding Systems

Injection Molds

Molding Machine Size

Molding Cycle Time

Mold Cost Estimation

Mold Cost Point System

Estimation of the Optimum Number of Cavities

Design Example

Insert Molding

Design Guidelines

Assembly Techniques

Design for Sheet Metalworking

Dedicated Dies and Pressworking

Press Selection

Turret Pressworking

Press Brake Operations

Design Rules

Design for Die Casting

Die Casting Alloys

The Die Casting Cycle

Die Casting Machines

Die Casting Dies


Auxiliary Equipment for Automation

Determination of the Optimum Number of Cavities

Determination of Appropriate Machine Size

Die Casting Cycle Time Estimation

Die Cost Estimation

Assembly Techniques

Design Principles

Design for Powder Metal Processing

Main Stages in the Powder Metallurgy Process

Secondary Manufacturing Stages

Compaction Characteristics of Powders

Tooling for Powder Compaction

Presses for Powder Compaction

Form of Powder Metal Parts

Sintering Equipment Characteristics

Materials for Powder Metal Processing

Contributions to Basic Powder Metallurgy Manufacturing Costs

Modifications for Infiltrated Materials

Impregnation, Heat Treatment, Tumbling, Steam Treatment, and Other Surface Treatments

Some Design Guidelines for Powder Metal Parts

Powder Injection Molding

Design for Sand Casting

Sand Casting Alloys

Basic Characteristics and Mold Preparation

Sand Cores

Melting and Pouring of Metal

Cleaning of Castings

Cost Estimating

Design Rules for Sand Castings

Example Calculations

Design for Investment Casting

Process Overview

Pattern Materials

Pattern Injection Machines

Pattern Molds

Pattern and Cluster Assembly

The Ceramic Shell-Mold

Ceramic Cores

Pattern Meltout

Pattern Burnout and Mold Firing

Knockout and Cleaning

Cutoff and Finishing

Pattern and Core Material Cost

Wax Pattern Injection Cost

Fill Time

Cooling Time

Ejection and Reset Time

Process Cost per Pattern or Core

Estimating Core Injection Cost

Pattern and Core Mold Cost

Core Mold Cost

Pattern and Cluster Assembly Cost

Number of Parts per Cluster

Pattern Piece Cost

Cleaning and Etching

Shell Mold Material Cost

Investing the Pattern Cluster

Pattern Meltout

Burnout, Sinter, and Preheat

Total Shell Mold Cost

Cost to Melt Metal

Raw Base Metal Cost

Ready-to-Pour Liquid Metal Cost

Pouring Cost

Final Material Cost




Design Guidelines

Design for Hot Forging

Characteristics of the Forging Process

The Role of Flash in Forging

Forging Allowances

Preforming During Forging

Flash Removal

Classification of Forgings

Forging Equipment

Classification of Materials

Forging Costs

Forging Die Costs

Die Life and Tool Replacement Costs

Costs of Flash Removal

Other Forging Costs



Subject Categories

BISAC Subject Codes/Headings:
SCIENCE / Mechanics / General
TECHNOLOGY & ENGINEERING / Industrial Design / General