DFM Design for manufacturing

Minimize the differences between the art of designing and the act of manufacturing a product with EnCata. Using the practice of DFM (Design For Manufacturing) and DFA (Design For Assembly), we develop products taking into account the limitations of manufacturing. Design your product so that it can prove its manufacturability and be assembled smoothly even before it reaches the manufacturing stage.

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Design for Manufacturing and Assembly

As one of the most significant parts of an engineering prototype in terms of manufacturability, design for manufacturing (DFM) is refining the design of plastic and metal parts for large-scale production. During the process of design for manufacturing and assembly, we develop parts, components, and products to ease manufacturing. By simplifying, optimizing and improving product design for manufacturing, we can create a superior device or system at a lower cost.

60+ Engineers

We act as your extended R&D team which is faster than hiring engineers locally. The breadth of our technical expertise is unique.

Development Speed

Our dedicated team is ready to scale up quickly. We utilize AGILE lean development process that leads to 30-50% faster delivery.

Burn rate


Our development location enables us to be cost-effective and deliver premium R&D and engineering services at 1/3 of the price compared to that of in N-W Europe and USA.

Design Engineering

Product design and development services

Design for manufacturing and assembly (DFMA) is a combination of two methodologies. Design for manufacturing (DFM) and design for assembly (DFA) enables a product design to be efficiently produced and easily assembled with minimal labor costs. General principles of DFMA include:

standardization of materials, components, and parts, 
reducing the number of parts, production, and assembly operations to save costs,
design simplicity, to reduce the complication or number of parts required, and setup time reduction.

DFMA usually follows basic engineering principles to reduce overall manufacturing cost and deliver products that satisfy customers. All of these principles are included in the DFX design for manufacturing. DFX is the application of rules, guidelines, and methodologies during new product development, with the purpose of impacting its value and meeting the requirements of a new product design. In many fields, “X” may represent several characteristics or features like manufacturability, power, variability, cost, yield, or reliability. This introduces such terms as design for manufacturability (DFM), design for assembly (DFA), design for inspection (DFI), design for variability (DFV), and design for cost (DFC).

Our team of engineers works regularly on design and manufacturing engineering projects. We apply product manufacturing and assembly methods simultaneously with the design, thus the Client can get the project deliverables in the shortest time and with minimal risks. Devices created according to the principles of DFM are easy to manufacture and maintain. They meet all the requirements for durability and functional qualities. The Client expectations dictate changes in the product design parameters related to the manufacturing process. Nonetheless, the project goal is basically the same — to create the product ready for manufacturing. The project technical results will increase efficiency, manufacturability, and usability of the future product.

Idea & Concept Development

By defining an idea first, you will ensure that your product has value and offers a solution to potential customers. The process of developing a concept will prove that the proposed solution works. It all leads to understanding the design requirements for additive manufacturing firstly. Then it helps you to set up the DFM checklist and make sure you are on the right path in your product development and contract manufacturing a product of high quality.

Rapid Prototyping

Check the correctness of the technical solutions for your product with Rapid Prototyping at EnCata. We use our rapid prototyping machines to turn our designs into physical reality in a variety of low-cost materials. This is a part of our effort to reduce risks before committing to mass production.

Reverse Engineering

Using reverse engineering gives obvious benefits. Since you are not reinventing the wheel during the mechanical design stage, you are both saving time and reducing the costs. Reverse engineering is not a good option for the main features of a product. In this case, your product will always fall  behind your competitors.

Low volume Manufacturing

EnCata is ready to help you in small-batch manufacturing. Low volume manufacturing is very sensitive to used equipment and tooling, COGS and lead time. Large producers are usually not flexible during negotiations on small orders. EnCata has in-house production facility where we can prepare the first small batch, make several hundreds of PCBAs, assemble products and test them before shipment.

Firmware Development

Asking for our contract electronics manufacturing services at an early stage will get you the edge over your competitors. We understand the critical importance of DFM and DFA for efficiency, speed, and high rates of production in the earliest stages of product development. At last, your firmware development product will meet all of your expectations.

Hardware Development (NPD Consulting included)

DFM occurs early in product development as an essential step before proceeding with high-volume manufacturing. Product development with EnCata, on a contract manufacturing services basis, is an enabling business relationship model, discovering customer needs, and finding market opportunities through our technical thinking and experience.

Design for manufacturability

Clients often turn to us with the desire to design a product that will be easily and cost-effectively manufactured. Such requests in most cases refer to the design for Manufacturing and Assembly. Hardware products’ DFM consider design development, manufacturing process, and product testing. It simplifies the production processes, and thereby reduces the overall cost of the product. DFA, in turn, will reduce the product’s assembly time by minimizing the number of assembly steps.

Design for Manufacturing and Assembly can also enable the identification, quantification, and elimination of waste or inefficiencies at various steps throughout the manufacturing and production process. It may additionally be used as a method of benchmarking and, in doing so, a company can assess the products of competitors.

Product Development Technology Stack

PCBA design

PCB board design: Analog, digital, optical, and RF design
2D drawings and engineering documentation

3D modeling and assemblies
3D CAD Design & Modeling

FEA and CFD simulations


Injection molding
CNC milling

Laser cutting
Polymer coating


Engagement Models

We focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

Some hardware Projects we delivered

Work that highlights the incredible technologies, solutions, and products EnCata developed.

Industries We serve

Our hardware engineers are focus on the entire product/service lifecycle, from concept to implementation to market launch.  EnCata’s knowledge, resources and innovation development expertise allow our Clients to develop and expand their businesses faster and leaner.

FAQ related to Product development

IP ownership when working with EnCata

When working with our clients we sign a contract where all the intellectual property to be generated during the R&D and engineering development belongs to the customer.

Do you sign NDAs?

Yes. As a highly professional design and engineering firm, we make sure that all discussions with our clients and all information regarding your invention, idea and other proprietary information are kept confidential.

How do I make sure EnCata does not "steal" my idea?

Aside from being a reputable company which does not steal ideas, EnCata's entire business model is based on delivering premium R&D, design and industrial prototyping services to our clients. As soon as we stole one client’s idea, our entire business would be ruined. Also, as we are not contract manufacturers (OEM or ODM), we wouldn’t be able to benefit from a stolen idea even if we wanted to.  This is definitely not a worry for our clients.

Patent or Develop first?

We follow a LEAN approach in product and business development and thus we strongly recommend patent filings only after you are  at least part-way through development. This is because patenting is expensive and early patents can already become obsolete or irrelevant later in the development phase. Typically, EnCata's work generates many patentable opportunities for our clients  and the best strategy is to file patents at TRL-7, i.e. when early beta prototype is ready and when a startup is ready to start batch production and marketing.

There is, however, another strategy, which is to use provisional patents which can be loose and are not to be disclosed to the public for 18 months. These are much less expensive and time consuming, generally costing below $500. EnCata will always sign a Non-Disclosure Agreement and keep your intellectual property confidential during the development phase and then we can recommend several third-party patent attorneys when the time is right.

Can EnCata consult me or help me with my existing design?

Whether you need to validate, evaluate or review your design, concept, 3D model, BOM or drawings, our experienced manufacturing, mechanical and electronics engineers are ready to help.

EnCata’s engineering consultancy service will allow you to critically reassess your project and help reach your goals while keeping the process cost-effective. To read more about the TRL and learn why it is useful, please procees to our blog.

What are typical project EnCata engaged with?

EnCata develops integrated Hardware and Software solutions for a variety of industries. We are engaged in multiple domains like IoT, robotics, medTech and IoMT, aerospace, agriculture, consumer products and many others. It is possible to work with such a wide variety of industries because we have multidomain expertise and utilize a cross-disciplinary product development approach.

I would like to do prototyping myself. Is it possible with EnCata?

Generally speaking, we do not allow clients to work on EnCata's manufacturing premises.

What does work, however, is that EnCata can manufacture prototype parts and the startup team can assemble thea prototype in our MakeIT Center hackerspace.  Alternatively, the startup can design and build the prototype themselves in our hackerspace.  We operate this free-access space in Minsk and we are currently working on expanding a hackerspace network worldwide.

Have a project to do? Reach out to EnCata team

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