DITAIEngineering case · Design discussion
The prototype defined the appearance. The manufacturing details still needed a conversation.
A customer approached us with printed prototypes and CAD for exterior equipment panels. They wanted thermoformed parts with a high-quality visible surface and a good fit between panels.
We reviewed the drawings and sent back specific proposals for the attachment features, trimming, assembly and finish. This case covers that DFM discussion and quotation planning.
- Application
- Exterior equipment panels
- Work completed
- Drawing review and DFM feedback
- Stage
- Proposal discussion · Before tooling
Inside this review
01 / Understanding the brief
The visible surface had to stay unchanged
The prototype CAD carried material and thickness notes that differed from the proposed thermoformed parts. The customer asked us to keep the outer surface as the design reference and take the thickness change from the back.
We acknowledged that requirement. The review then focused on the features that could be revised while retaining the appearance the customer wanted.
02 / Making the proposal specific
We showed another route for the attachment features
For selected features, we proposed separate CNC-machined components bonded to the formed shells. We marked the affected areas on the models and asked for those features to be separated in the design.
We also identified sharp internal trim corners that needed a radius for the round CNC cutter.
The workshop photographs made the bonding proposal easier to discuss. Together with the marked-up views, they showed the customer which features we meant and how we proposed making them.
We invited feedback and alternative ideas. The changes still needed the customer’s agreement.
03 / Connecting fit and finish
Before painting, we wanted to check the assembly
The customer asked about coloured sheet versus a painted finish. Because several panels had to fit together, we requested the mating metal structure and proposed checking the complete assembly in-house.
The sequence below was our proposal—not work already completed.
- 01 →AssembleFit the panels to the mating structure.
- 02 →Check & adjustReview the fit and make adjustments.
- 03Prepare & paintCarry out final surface preparation and painting.
04 / Being clear about limits
The texture was not an exact match. We said so.
We proposed exterior-grade capped ABS for consideration. For texture, our existing sheet options did not exactly match the customer’s reference. We offered alternatives and asked whether one would be acceptable.
We also outlined separate quotation items for tooling, samples and later production. Parts pricing would be ex-works; packing and indicative freight estimates would be checked separately.
The next step was to agree the drawing changes, assembly approach, material and finish choices before moving towards tooling and sample work.
Have prototype CAD ready for review?
Share the model, mating-part information and appearance requirements. We can discuss the manufacturing details together.
An anonymised design-review case. Customer identity, product drawings and commercial details are withheld. Workshop photos illustrate the proposed process, not customer parts or completed project results.
Have a Thermoforming Project?
Send a drawing or sample for a free DFM review, with flexible quantities from prototype to production. Initial reply within 8 working hours. Preliminary DFM normally within 24–48 hours after sufficient project information is received. Formal quotation timing depends on project complexity.
