KED Engineering Blog

Designing smarter, making cheaper

Practical articles on TRIZ, DFM & DFA, mechanisms, static load analysis, plastic parts, CNC, sheet laser, brackets, jigs — and how small design decisions cut manufacturing cost.

What is TRIZ? The Systematic Way to Invent

Featured

Innovation 5 min read

What is TRIZ? The Systematic Way to Invent

TRIZ turns invention from guesswork into a repeatable method. Here is how it works and why engineers should care.

Read article

Innovation 6 min read

The 40 Inventive Principles of TRIZ

The 40 principles are reusable solution patterns extracted from patents. They turn vague creativity into a checklist of proven moves.

Mechanisms 5 min read

Mechanisms Comparison: Gears vs Belts vs Chains

Power transmission is one of the first decisions in a mechanism. Each option trades off cost, precision, noise, and maintenance.

Mechanisms 5 min read

Linkage Mechanisms: The 4-Bar and Beyond

Linkages convert one motion into another using only rigid links and joints — the quiet workhorses of mechanical design.

Mechanisms 4 min read

Cam and Follower Design Basics

Cams produce precise, repeating output motion from a rotating input. When the motion profile must be exact, a cam is often the cleanest answer.

Analysis 6 min read

Static Load Case Study: A Wall Bracket

A bracket holding 50 kg looks simple — until you ask where it fails. A static load study tells you before you build.

Analysis 5 min read

How FEA Helps You Trust a Design

FEA turns I think it is strong enough into here is the factor of safety — and filters bad designs before you cut metal.

DFM 5 min read

What is DFM? Design for Manufacturing

DFM means designing a part so it is easy and cheap to make — a mindset applied from the first sketch, not a cleanup at the end.

DFM 4 min read

10 DFM Rules That Cut Cost

Each rule is a small decision that, multiplied across a product, becomes a large saving.

DFA 4 min read

What is DFA? Design for Assembly

DFA focuses on how easy a product is to put together. Fewer parts and fewer steps mean cheaper, more reliable assembly.

DFA 4 min read

DFA in Practice: Reduce Part Count

The simplest DFA question: does this part need to be a separate part? If not, make it part of something else.

DFM 5 min read

DFM vs DFA: Finding the Balance

DFM asks if each part is easy to make. DFA asks if the whole product is easy to assemble. Sometimes they pull in opposite directions.

Plastics 6 min read

Plastic Part Design for Injection Molding

Injection molding is the cheapest way to make a million parts — and the most punishing way to design a bad one.

Plastics 5 min read

Draft, Ribs, and Bosses in Plastic Parts

Three features that make or break a plastic part — and the common mistake that turns stiffness into sink marks.

CNC 5 min read

CNC Machining: When and Why

CNC removes material from a solid block — precise, flexible, and needs no tooling. Perfect for low volumes and complex geometry.

CNC 4 min read

CNC Tolerances and Cost

A tolerance is a promise to spend money. Every decimal place of precision costs exponentially more.

Sheet Metal 5 min read

Sheet Metal Laser Cutting Basics

A fiber laser cuts flat sheet with no tooling and fast setup — the default for brackets, enclosures, and flat parts.

Sheet Metal 5 min read

Designing Sheet Metal Brackets for Laser Cutting

A bracket is a flat shape that becomes 3D with a bend. Designing it well means designing the flat blank well.

Sheet Metal 4 min read

Bend Relief and K-Factor in Sheet Metal

When sheet bends, the outside stretches and the inside compresses. Two concepts decide whether your blank unfolds to the right size.

Tooling 4 min read

Jigs vs Fixtures: What is the Difference?

The words get used interchangeably, but they do different jobs — and the difference matters in the shop.

Tooling 5 min read

Designing a Welding Jig

A welding jig holds parts in position while they are welded. Its job is to control heat distortion and keep assemblies consistent.

Cost 6 min read

How a Small Design Change Cuts Manufacturing Cost

A deep pocket existed only to clear a cable. We rerouted the cable and removed the pocket — part cost dropped 65%.

Cost 5 min read

Tolerance Stack-Up and Cost

Tolerances do not just cost money individually — they stack. A stack-up analysis, done early, often reveals hidden over-tolerancing.

Materials 5 min read

Material Selection Drives Cost

The material is often the first cost decision and the last one revisited. The best material for performance is rarely the cheapest that still works.

Process 5 min read

From Prototype to Production: A Checklist

Moving from one prototype to a production run is where most cost is locked in. A short checklist keeps it disciplined.