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The largest EMS in the Silicon Valley

Call for a Quote (510) 580-8500

Or Email Us at

The largest EMS in
the Silicon Valley

Tag: dfm


PCBA – Design for Manufacturability

Whenever you bring a new product to market, there are many considerations and iterations required to find the optimal design. A key element that designers often don’t consider early enough is the ease of manufacturing the final product. When you’re focusing on adding functionality and improving the product’s durability, the PCB’s assembly requirements may seem inconsequential. However, design for manufacturability (DFM) is crucial to ensure the successful launch of your product.

What Is Design for Manufacturability?

Two distinct processes ensure your product’s manufacturability. Applying design for assembly (DFA) and design for fabrication (DFF) principles early in the product development process will save a lot of iterations and rework when finalizing the design.

Design for Fabrication

DFF focuses on issues relating to the fabrication of the boards. With DFF, the board’s layout considers not just the lines and bond dimensions but includes solving issues such as heat dissipation, connector location and any possible future updates to the product. By applying DFF design considerations early, you optimize both the PCB’s layout and cost before moving to the manufacturing stages.

Design for Assembly

Once you’ve optimized the DFF of the board, you’ll need to find the best assembly process for the final product. DFA ensures you develop the manufacturing process instructions (MPIs) that will make your product’s assembly run efficiently. Here at Sonic Manufacturing Technologies, we assist you by developing the required MPIs directly on an active production line.

Whether it’s a demo or development board, using active production lines during the prototype stages will ensure you find the optimal assembly processes early. It will also highlight any design deficiencies before they become showstoppers in the product’s manufacturing lifecycle.

Why You Need DFM for Your Printed Circuit Board

Design teams often leave the manufacturing considerations to the vendor. Once the vendor receives the design, they’ll conduct a manufacturability analysis and make the necessary changes to optimize the assembly process. If any disconnection exists between the designers and the manufacturing company, they may neglect communicating all the changes to the design team.

The impact of these changes could have drastic effects on the final product’s functionality. To eliminate the risks associated with this, getting the manufacturer involved early and collaborating with them during every iteration of the design is essential.

Sonic Manufacturing’s PCBA Design for Manufacturability Services

Sonic Manufacturing Technologies uses state of the art production lines to develop the MPIs and optimize the layout of the design. Our engineers can highlight any issues with the initial design and suggest changes that’ll improve your product’s feasibility.

Our services include:

At Sonic Manufacturing, we use an agile manufacturing process to ensure changes and updates do not disrupt any production runs. Additionally, our in-house engineering team will ensure you find an optimized assembly process for the product by developing an efficient MPI for any prototype or demo board.

Take Advantage of Sonic’s Manufacturing Optimization Processes

To guarantee your next product’s successful launch, partner with Sonic Manufacturing to ensure a smooth and efficient development process. Our state-of-the-art facility enables design teams to test designs and find optimized solutions for your product during the early stages of development.

When you need to optimize the design of a solid PCB, a flex board, or a combination of the two, you should get in touch with Sonic Manufacturing Technology’s talented team today.

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Considerations in Electronic Box Build Services

Inordinate amounts of considerations go into finding the perfect industrial design for your latest product. Is it functional? Does it serve an innovative need? Can it be cheaper? How long will it take to source from the manufacturer and assembler? All of these questions influence the final specification and layout of the product and are vital considerations in electronic box build services. Antoine de Saint-Exupéry famously said that you achieve perfection not when you have nothing more to add, but instead when there’s nothing left for you to take away from your creation.

The perfect design doesn’t just emphasize the functionality and usability of a product, it includes the aesthetics and user experience as core principles involved during the entire design lifecycle. The founder of Braun, Dieter Rams, established ten design considerations for engineers to subject each new product specification against before moving to the production phase.

Innovative Approaches to Electronic Box Build Services

A balance exists between creating something that is utilizable without compromising on its appearance. It should preferably also leave a lasting impression on end-users, fostering brand recognition in the longer term, and be designed for manufacturing with reduced errors and high efficiency. This may sound like a fantasy in traditional design and manufacturing cycles, as the next launch is always too soon, and the market’s expectations are too great to achieve a viable turn-around within these constraints.

This is exactly why agile design and manufacturing provides a new and innovative approach that helps product designers succeed in achieving such lofty goals. With agility as a cornerstone of the design and build lifecycle, entrepreneurs, startups, and established product designers can create continuous cycles of innovation and product improvement.

Sonic Manufacturing’s Agile Supply Chain and Electronic Manufacturing Services

At Sonic Manufacturing, we don’t necessarily consider change as a bad thing when collaborating with customers for electronic box build services. In fact, we may recommend a different backplane assembly or improve on your box frame and connector selections during the prototype or manufacturing stages. The primary goal is to improve your final product’s manufacturability and reliability, as well as accommodating for innovations discovered after your initial release to market.

Working with our customers, we assist with the initial wiring diagram creation and provide product layout services to find the perfect balance between function and aesthetic. As we prototype directly on the production line, the final specification includes all DFMA (Design for Manufacturability and Assembly) considerations at the outset of the project. Sonic Manufacturing understands that good ideas often come after the fact, and we designed our processes specifically to accommodate these situations.

Sonic Manufacturing’s electronic box build services include:

  • Product layout and assembly prototyping.
  • Housing design and weather tight finishing.
  • Supply chain logistics optimization with automated ecommerce solutions.
  • Adaptable forecasting and daily special runs.
  • Outbound and reverse logistics for improved order fulfillment.

Although our facility is in the US, we can ship products anywhere around the globe. We can also source components from the major OEM manufacturing zones using our International Procurement Office situated in Singapore.

Sonic Manufacturing as Your Agile Electronic Manufacturing Company

Sonic Manufacturing uses flexible, high-speed lines that assist with New Product Introduction as well as JIT or Kanban manufacturing processes for any level of volume. With our ecommerce component sourcing solution that handles the bulk of our procurement tasks, our team is free to focus on the primary goal of bringing your idea to fruition and find the perfect design for a sustainable product.

For more information regarding the primary considerations in electronic box build services, as well as product layout and manufacturing optimization, speak to one of Sonic Manufacturing’s expert production engineers today.

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New Product Introduction & Design for Manufacturing

The process of engineering a new product at an incubator, lab, or startup is an exciting time. Perhaps your ultimate objective is to increase revenue, improve quality, or introduce innovation. No matter what, design engineering is critical, but successfully taking a new product to market is an equally complex process.
Moving from proof of concept (PoC) to full-scale production demands a high level of quality from beginning to end. That’s why mastering the new product introduction lifecycle starting with design for manufacturing (DFM) is essential to improve the odds for success.
We’ll go over the process for new product introduction below as well as how DFM at Sonic can help your project succeed.

New Product Introduction

Prototyping is always a challenge. For a new product to justify your efforts, however, it demands the ability to manufacture thousands of it at a time. Plus, all these must meet the specification requirements right out of the box.
Sonic has the capabilities to complete all six steps below in the new product introduction process thanks to our state-of-the-art, 85K-square-foot production facility in Fremont, California. This includes meeting industry standards for both low and high-volume manufacturing.

1. DFM

The Sonic manufacturing team evaluates your product’s design to determine the optimal processes to build and test it. This phase is critical as any necessary changes identified later will be more difficult and costlier to implement.

2. Parts Availability

An availability analysis determines how easily parts can be obtained as well as their cost. At this point, any potential issues identified in the supply chain can be addressed.

3. Engineering Verification

An initial build out is produced. This probably isn’t what the final product will look like, and it may not even be in a housing. Instead, the primary goal is design testing, especially of printed circuit boards (PCBs).

4. Testing

Once the initial PCBs are validated, additional testing systems are employed. These will move beyond design testing into areas including durability, safety, and reliability.

5. Design Verification

The next build will be much closer to how the finished product will look. To save money at this stage, however, 3D printing may be employed to fine-tune the final design before more expensive materials and complex manufacturing processes are used.

6. Product Validation

The final build is a dry run for the full-fledged manufacturing process. This includes not just the product, but packaging for both shipping and unit sales. Once your product and its manufacturing process are validated, you’re ready to begin full-scale production.

DFM at Sonic

Each step in the new product introduction process is important but beginning with expert DFM is critical to be successful. That’s why DFM at Sonic is your best choice.
DFM at Sonic provides you with key advantages:

  • Prototype deliveries ranging from two days to two weeks depending on complexity and product needs
  • More than 30 engineers on staff to provide development and support services
  • Extensive experience working in multiple industries including aerospace, automotive, biomedical, computing, and defense

Plus, when you choose DFM at Sonic, you’re working with an agile team which can procure any necessary parts quickly and is flexible enough to meet your schedule as it changes.

The Sonic Advantage

At Sonic, we understand the pressures incubators, labs, and startups face: compressed development times coupled with the need to bring products to market as soon as possible. When there’s no room for error, that’s when you can count on Sonic.
Sonic Manufacturing serves clients from Silicon Valley to Salt Lake City to Sacramento. Request a quote today by calling, emailing, or using our Request a Quote form.

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