Boothroyd Dewhurst Releases “DFMA 2025B” Software

EAST GREENWICH, R.I., USA, December 17, 2025 — Boothroyd Dewhurst Inc. is pleased to announce the launch of DFMA 2025B, featuring new capabilities designed to help manufacturers understand how global cost variations can affect product design, sourcing decisions, and overall profitability.

The centerpiece of DFMA 2025B is DFMA Global Costing Data, an optional add-on that brings more than 200,000 cost data points into DFMA’s existing cost models. Each region’s dataset includes up-to-date machine rates, labor costs, material prices, tooling and energy expenses, and ancillary supply costs—applied directly inside DFMA to enable consistent, apples-to-apples cost comparisons for parts and assemblies across multiple regions.

A complete view of potential costs, worldwide

DFMA Global Costing Data provides coverage across major manufacturing centers and industrial hubs in 22 countries:

• United States
• South Korea
• Italy
• Germany
• China
• Japan
• Spain
• Israel
• Mexico
• Indonesia
• Taiwan
• Brazil
• Canada
• Ireland
• Poland
• El Salvador
• Vietnam
• United Kingdom
• Czech Republic
• India
• France
• Switzerland

Real insights—not educated guesses

Other tools may claim “global cost libraries,” but many rely on generic figures, unverified third-party data, or percentage markups applied to base costs—approaches that can obscure critical real-world differences in process drivers, material behavior, energy consumption, tooling effects, and other factors.

DFMA Global Costing Data is compiled using the same intensive research and logic that underpins DFMA cost models. Boothroyd Dewhurst experts use AI and data analytics to track current manufacturing trends, then evaluate and calibrate results against time-tested data—resulting in a consistent, accurate global framework that predicts costs for numerous materials and operations.

Supported operations and processes

DFMA Global Costing Data helps predict costs across a wide range of manufacturing activities, including:

• Six types of metal casting
• Machining
• Manual and automatic assembly
• Powdered metallurgy
• Sheet metalworking
• Printed circuit board processing
• Plastic and metal extrusion
• Forging
• Plastic and metal injection molding

What you can do with DFMA Global Costing Data

With a broader global perspective, teams can:

• Determine which regions offer the best prices for individual parts or assemblies
• Build business cases for major decisions such as supply chain investments
• Re-evaluate current sourcing and manufacturing choices against today’s prices
• Enhance communication and negotiation with suppliers using clear, specific data
• Design more cost-effective products by optimizing regional costs early in development

In practice, engineers can compare costs for the same model across regions—revealing the impact of key drivers such as material, setup, processing, and even tariffs—before making sourcing or design decisions.

Process and material selection updates

To support the expanded dataset, DFMA 2025B includes updated process and material selection screens that are streamlined and reorganized to scale cleanly as additional country datasets are added.

Reliability, compatibility, and performance improvements

DFMA 2025B also includes improvements focused on overall stability and consistency, particularly in areas that interact with Global Costing Data. Updates to cost libraries and tooling data improve consistency between library values and active models, including better handling of tool material settings when library data is reloaded.

Enhancements to Dynamic Cost Agent for Machining improve compatibility and region-driven behavior when opening older models in 2025B. Legacy controls are upgraded cleanly, insertion behavior is more consistent, and dynamic machines update reliably to reflect rates from the currently selected country so regional comparisons align with the intended dataset.

Reporting has been made more robust, including fixes to avoid rare crashes and to ensure DFM summary outputs generate reliably across a wider range of models.

“DFMA 2025B puts manufacturing cost data into a clear global context,” said Nick Dewhurst, President of Boothroyd Dewhurst. “With Global Costing Data integrated directly into DFMA, teams can make more informed sourcing, design, and manufacturing decisions—minimizing expenses and improving profitability.”

Availability

For current DFMA software subscribers, DFMA Global Costing Data is available as a paid upgrade. The global costing data is included with all new DFMA software subscriptions. For more information, contact Boothroyd Dewhurst at info@dfma.com.

DFMA^® is a registered trademark of Boothroyd Dewhurst, Inc.

About Boothroyd Dewhurst, Inc.

Boothroyd Dewhurst, Inc. was the first company to commercialize Design for Manufacture and Assembly (DFMA) methodologies and software tools, which make it possible to evaluate, estimate, and reduce the manufacturing cost of a product in the design phase through product simplification and cost estimation. Hundreds of Fortune 1000 companies, including Dell, John Deere, and Boeing, use DFMA to cut the costs of their manufactured products and achieve design innovation in their markets. The company was founded in 1983 and received the National Medal of Technology Award in 1991. For more information about DFMA software, workshops, consulting services, and international conferences, contact Boothroyd Dewhurst, Inc., 4474 Post Road, East Greenwich, R.I. 02818, USA. Tel. (401) 783-5840. Web site: www.dfma.com. E-mail: info@dfma.com.

DFMA 2025B introduces Global Costing Data (optional add-on)

Streamlined process & material selection for expanded global options