Expert DFM Insights from Our Welding Services Team

Welding is one of the most critical and complex aspects of sheet metal fabrication. At GTR Manufacturing, our certified welders perform MIG, TIG, and spot welding with precision and consistency. But even with our expert welding services team and state-of-the-art equipment, design decisions make a big difference to your project’s success.

That’s why our team is sharing a few design for manufacturing (DFM) insights to help you get the best possible results. With these tips, you can reduce production time and avoid unnecessary costs on your next project. 

1. When Possible, Choose Forming Over Welding

Even as our team excels at welding, forming is often the faster and more cost-effective choice. Formed parts typically have greater strength and a cleaner overall appearance. Because forming involves fewer manual operations, it also reduces labor time and more easily leads to consistent results.

Aluminum, for instance, tends to distort under heat. While our team can still achieve precise, attractive welds, those results often require extensive preparation and additional metal finishing processes. Whenever your part’s design allows it, forming is usually the best solution, especially if aesthetics are a priority. We have a memorable saying we tell customers: “If you want it neat, avoid the heat.”

2. Collaborate Early to Determine the Right Weld Type

One of the most common DFM issues we encounter is inefficient weld specifications on drawings. For example, some designs call out a number of plug welds in cases where spot welding would be faster and more cost-effective. 

We often work with these customers to make the design changes, but it’s always critical to ensure the change is made early in your process before a design is locked in. In the design phase, relatively simple changes can reduce production time and total cost.

3. Remember That Large Welds Multiply Costs in Production

A design that includes long or heavy welds may not seem costly during prototyping, but at production scale, those added welds can dramatically increase labor hours and total project costs. As a company that operates in both prototyping and production, we always try to help customers take the long view from the start.

Small inefficiencies in prototyping become magnified in production when multiplied across hundreds or thousands of parts. And once a part enters production, changing weld specifications can be more difficult than in the prototyping phase. That adds significant time and expense right when you’re aiming to complete your project or enter the market.

Expert Welding Services at GTR Manufacturing

While many of our DFM welding tips focus on reducing welds, there’s no substitute for expert craftsmanship when welding is required. Our certified team handles a wide range of techniques, including MIG, TIG and spot welding. We also leverage creative joining methods such as slot-and-tab construction in tandem with welding.

Because heat can cause distortion, our welders work closely with our engineering team to account for that in every step, ensuring parts always conform to your specifications. We also invest in advanced welding technologies and ongoing training to stay on the cutting-edge of welding precision.

Request a Quote

Whether you need expert welding services, CNC machining, or complete electromechanical assembly, GTR Manufacturing is ready to help. Contact us today to request a quote or discuss how our DFM insights can lower your next project’s costs!