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

At EnCata, what kinds of contracts do you use? Is it a fixed-term or an agile contract?

EnCata works with both fixed term and agile contracts.

What should I do now that I've approached you with my project idea?

1. Once you have approached us with the project, we conclude the NDA and send the information to the Sales Manager for further evaluation and project planning.
2. The Sales Manager or Sales Engineer will contact you to clarify your goals, requirements and tasks to accomplish. This process is very close to business analysis. When the details are agreed with you, a cost estimate and a quotation are prepared.
3. If you accept the quotation, we will prepare a Technical design specification to document scope of work and requirements and conclude an agreement.
4. After we've signed the agreements, we'll assign you a Project Manager who will gather a project team and report on the project progress.

Can you provide me with a certification of competence?

EnCata employs around 30 engineers with Master's and PhD degrees in electrical and industrial design, mechanical engineering, prototyping and manufacturing from European universities. Each employee is an expert in his or her field.

What level of training do your specialists have?

The majority of specialists are of middle or senior levels. Their range of influence is broad enough to encompass the entire new product lifecycle. Our specialists resolve legal and certification difficulties during the concept stage, optimize production costs during the 3D model development process and create necessary documentation for firmware support. Juniors make up only 15% of the team. They constantly upgrade their qualifications under the supervision of seniors.

Is it possible for us to cooperate with EnCata’s team?

EnCata is always willing to work with its client. We have everything we need to create a collaborative site. Both parties can work on the project simultaneously. The Customer, for instance, and his/ her team designs the electronics while we work on the enclosure. When teams work together to achieve a fantastic result, it is always a win scenario.

Is it possible to discuss the project with your technical team?

EnCata’s team is always willing to discuss all the necessary details about the project proposed. Our full-fledged team of professionals will interrogate you until both parties are satisfied with the procedures necessary to complete the job.

Can EnCata facilitate mass production?

It certainly can. For any product, EnCata creates a design documentation package and a process documentation package that is suited to the production. It should be noted, however, that the technologists at the customer's chosen plant may make changes or impose their own requirements on the documentation design. EnCata, in turn, makes it easier for the client and the technologist to communicate. EnCata does not mass produce, although it can undertake small-scale production at the request of customers.

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.

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.

Does EnCata outsource electronics services?

Our in-house professionals handle almost all electronics work, including interface design, protocol development, communication design, schematic design, PCB Design, Firmware design and battery management. If the Customer requires a service that Encata does not supply, we have partners that can meet that need.

Do you write program code, either software or firmware?

We certainly do. EnCata employs electronics specialists who deal with low-level firmware. We also have experts on staff who can implement high-level software code.

Are there hardware engineers in your team?

EnCata employs 12 mechanical and industrial designers and 10 electrical engineers with experience in hardware and firmware. Our team consists of middle and senior level engineers, who have 5+ years of field expertise and have already completed more than 300 projects.

Can EnCata help me with fundraising?

We do indeed help with fundraising through our large business network. However, we typically recommend startups to our partner VCs after we have done some work for the startup and learned more about the team and their core technology. This feedback and recommendation is of great value to all of the friendly VCs as it saves them much time and effort for due diligence.

Have a project to do? Reach out to EnCata team

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