DFMA^® Resources

DFMA^® stands for Design for Manufacture and Assembly. It integrates two methodologies — Design for Assembly (DFA) and Design for Manufacture (DFM) — to help designers simplify product structure, reduce manufacturing and assembly costs, and improve quality by addressing both concerns from the outset. Developed by Dr. Geoffrey Boothroyd and Dr. Peter Dewhurst, DFMA^® provides data-driven tools for design and cost analysis that enable faster, more accurate decision-making.

DFMA^® software has two modules. DFMA Product Simplification is a product-structure analysis tool that simplifies designs by reducing part count and improving assembly efficiency. DFMA Should Costing is a should-costing tool that estimates manufacturing costs from geometry, process, and material inputs — helping teams minimize production costs and balance cost, quality, and manufacturability early in design.

DFMA^® applies to any electro-mechanical product requiring the manufacture and assembly of metallic or plastic components. It is used across automotive, aerospace, electronics, consumer goods, medical devices, and more. There is no evidence it is better suited to any particular industry.

No. While both involve function and cost, DFA keeps total product functionality static and achieves savings by using fewer, multi-functional parts. Value Engineering analyzes whether each function delivers sufficient value relative to cost. DFA focuses solely on assembly efficiency while preserving the designer's intended functionality.

No. Although basic DFMA principles can be learned conceptually, the methodology is data-driven and impractical without software. DFMA^® is a systematic, quantitative process — not a brainstorming exercise. The methodology and software have co-existed since enterprise software became prominent in the 1980s.

DFMA^® delivers cost reductions, improved product quality, and streamlined manufacturing. It helps engineers identify inefficiencies early — reducing production costs, shortening time-to-market, and minimizing costly late-stage redesigns. It also improves collaboration between design and manufacturing teams and supports better resource utilization and waste reduction.

Yes. By identifying manufacturing and assembly issues early in design, DFMA^® minimizes costly redesigns. Streamlined processes reduce lead times, allowing companies to bring higher-quality products to market faster.

DFMA^® promotes efficient use of materials and resources by optimizing designs for manufacturability — reducing waste, energy consumption, and environmental impact. The methodology encourages fewer parts, simpler assemblies, and designs that are easier to disassemble and recycle.

Pricing depends on your specific needs. Visit the Contact Us page to start the quoting process and a representative will follow up shortly.

We exclusively offer subscription licenses, available as floating or node-locked configurations. Floating licenses are server-hosted with a defined number of concurrent users — any number of people can access the software, limited only by simultaneous seats. Node-locked licenses are tied to a specific machine and work offline, ideal for users who travel frequently. Multi-year subscription commitments receive discounted pricing.

We offer fully functional evaluation licenses to qualified prospects following an initial consultation. Evaluations typically run for 30 days, giving your team enough time to assess the software against real projects. To begin the evaluation process, contact us and a representative will walk you through next steps.

Yes. We provide discounted annual subscription pricing for eligible institutions offering DFMA^®-related lab or coursework. Submit a Contact Us request for pricing.

Yes. We offer two-day training at our office in East Greenwich, RI, USA, and three-day on-site workshops. Programs cover basic through advanced functionality. See the Services page for details.

For DFMA Product Simplification, no manufacturing expertise is needed. For DFMA Should Costing, basic knowledge of the process being analyzed is helpful. The software builds a default process chart from dimensions or a CAD model, but important cost drivers often require user input. The cost-driver interface also serves as a learning tool for less experienced users.

DFMA Should Costing includes models for: Assembly Fabrication, Automatic Assembly, Blow Molding, Die Casting, Plastic Extrusion, Metal Extrusion, Hot Forging, Injection Molding, Investment Casting, Machining (covering many methods and operations), PCBA, Sand Casting, Sheet Metal, Foam Molding, Powder Metals, and Thermoforming.

Every DFMA Should Costing estimate is built fresh from manufacturing science applied to the geometry you provide — not from historical pricing. The primary output is a cycle time, combined with material costs and machine/labor rates to produce a cost result. This approach is typically more accurate than historical pricing and far less dependent on tracking market changes.

Yes. In addition to hard-coded data, four library types are included: material, operations, machines, and process parameters. Two manufacturing profiles ship with the software. All libraries are stored in XML format and can be accessed or modified by other programs.

We evaluate libraries for updates several times a year. Manufacturing input costs (machine rates, operator rates) change less frequently than most customers expect. Raw material prices are typically contract-negotiated between customer and supplier. For organizations needing to model fluctuations or contract rates, substantial customization is built in — all data is accessible within the software and via editable XML files.

Yes. An integrated CAD import accepts .step, .stp, .stl, and .iges formats. In DFMA Product Simplification, basic envelope dimensions are used. In DFMA Should Costing, cost-driver information for many processes is extracted automatically. Additional geometry can be selected directly on the model by the user.

Not necessarily. DFMA Should Costing estimates the manufacturing cost burden to a supplier. The price a supplier charges reflects additional market forces, so a gap is expected. When the analysis is consistent with the supplier's processes, the estimate is an excellent guide for identifying cost-reduction potential in negotiations.

We offer user manuals, video tutorials, and direct support via email and phone. Our technical support team provides guidance and troubleshooting for a wide range of issues.

Yes. Customization options include configuring specific manufacturing processes, integrating industry-specific data libraries, and developing custom reports. Our team works with customers to implement solutions for their unique requirements.

Most users become proficient within a few weeks to a few months, depending on experience and project complexity. Our training programs — online courses, in-person workshops, and on-site sessions — are designed to accelerate the learning process.

See the bottom of our Support Page for current PC system requirements.

No. Each analysis is a separate DFMA Product Simplification or DFMA Should Costing file. The only centralized data is in the material, machine, operations, and process parameters libraries, which do not store user-generated analysis data.

No. There is no communication between the DFMA^® software and Boothroyd Dewhurst, Inc. We only access analysis files if users provide them for support, typically under an NDA.

Yes. The data libraries and license server can both be accessed from cloud locations, and the software runs in many virtualization environments. Boothroyd Dewhurst does not currently provide active support for cloud deployments but can offer guidance on setup and compatibility.