459:(DFA) to reduce product manufacturing cost and increase manufacturing practicality. There are instances when this method could cause calendar delays since it consumes many hours of additional work such as the case of the need to prepare for design review presentations and documents. To address this, it is proposed that instead of periodic inspections, organizations could adopt the framework of empowerment, particularly at the stage of product development, wherein the senior management empowers the project leader to evaluate manufacturing processes and outcomes against expectations on product performance, cost, quality and development time. Experts, however, cite the necessity for the DFI because it is crucial in performance and
496:, is the need for temporary support structures for overhanging part features. Post-processing removal of these temporary support structures increases the overall cost of fabrication. Parts can be designed for additive manufacturing by eliminating or reducing the need for temporary support structures. This can be done by limiting the angle of overhanging structures to less than the limit of the given additive manufacturing machine, material, and process (for example, less than 70 degrees from vertical).
439:, the strength and stiffness of the tool which is determined in part by the length to diameter ratio of the tool will play the largest role in determining that speed. The shorter the tool is relative to its diameter the faster it can be fed through the material. A ratio of 3:1 (L:D) or under is optimum. If that ratio cannot be achieved, a solution like this depicted here can be used. For holes, the length to diameter ratio of the tools are less critical, but should still be kept under 10:1.
93:
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There are many other types of features which are more or less expensive to machine. Generally chamfers cost less to machine than radii on outer horizontal edges. 3D interpolation is used to create radii on edges that are not on the same plane which incur 10X the cost. Undercuts are more expensive to
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Metals come in all forms. In the case of aluminum as an example, bar stock and plate are the two most common forms from which machined parts are made. The size and shape of the component may determine which form of material must be used. It is common for engineering drawings to specify one form over
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A significant contributing factor to the cost of a machined component is the geometric tolerance to which the features must be made. The tighter the tolerance required, the more expensive the component will be to machine. When designing, specify the loosest tolerance that will serve the function of
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Each operation (flip of the part) has set-up time, machine time, time to load/unload tools, time to load/unload parts, and time to create the NC program for each operation. If a part has only 1 operation, then parts only have to be loaded/unloaded once. If it has 5 operations, then load/unload time
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components company, where inspection is mandatory, there is the requirement for the suitability of the manufacturing process for inspection. Here, a mechanism is adopted such as an inspectability index, which evaluates design proposals. Another example of DFI is the concept of cumulative count of
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The low hanging fruit is minimizing the number of operations (flip of the part) to create significant savings. For example, it may take only 2 minutes to machine the face of a small part, but it will take an hour to set the machine up to do it. Or, if there are 5 operations at 1.5 hours each, but
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As semiconductor technology scales to smaller nodes, transistors and interconnects become incredibly dense and sensitive to subtle variations in the manufacturing process. These variations can lead to defects that cause chips to malfunction or degrade their performance. DFM aims to minimize the
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process in order to reduce its manufacturing costs. DFM will allow potential problems to be fixed in the design phase which is the least expensive place to address them. Other factors may affect the manufacturability such as the type of raw material, the form of the raw material, dimensional
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products in such a way that they are easy to manufacture. The concept exists in almost all engineering disciplines, but the implementation differs widely depending on the manufacturing technology. DFM describes the process of designing or engineering a product in order to facilitate the
361:). Then the part must be flipped from side to side to machine all of the features. The geometry of the features dictates whether the part must be flipped over or not. The more ops (flip of the part), the more expensive the part because it incurs substantial set-up and load/unload time.
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the other. Bar stock is generally close to 1/2 of the cost of plate on a per pound basis. So although the material form isn't directly related to the geometry of the component, cost can be removed at the design stage by specifying the least expensive form of the material.
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Lastly, the volume (number of parts to machine) plays a critical role in amortizing the set-up time, programming time and other activities into the cost of the part. In the example above, the part in quantities of 10 could cost 7–10 times the cost in quantities of 100.
172:(IC) design to ensure that those designs transition smoothly into high-volume manufacturing with optimal yield and reliability. DFM focuses on anticipating potential fabrication issues and proactively modifying chip layouts and circuits to mitigate their impact.
434:
As machining is a subtractive process, the time to remove the material is a major factor in determining the machining cost. The volume and shape of the material to be removed as well as how fast the tools can be fed will determine the machining time. When using
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broadens the ability of a designer to optimize the design of a product or part (to save materials for example). Designs tailored for additive manufacturing are sometimes very different from designs tailored for machining or forming manufacturing operations.
220:
DFM aims to maximize yield, the percentage of chips that function correctly out of a manufactured wafer. This involves identifying critical areas of the design, adding redundancy, and implementing layout strategies that improve the likelihood of successful
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As manufacturing companies evolve and automate more and more stages of the processes, these processes tend to become cheaper. DFM is usually used to reduce these costs. For example, if a process may be done automatically by machines (i.e.
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DFM encompasses techniques to ensure chips are reliable throughout their expected lifespan. This involves analyzing how design choices impact electromigration, hot carrier injection, and other potential failure mechanisms, and designing
124:
Depending on various types of manufacturing processes there are set guidelines for DFM practices. These DFM guidelines help to precisely define various tolerances, rules and common manufacturing checks related to DFM.
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the component. Tolerances must be specified on a feature by feature basis. There are creative ways to engineer components with lower tolerances that still perform as well as ones with higher tolerances.
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489:
In addition, due to some size constraints of additive manufacturing machines, sometimes the related bigger designs are split into smaller sections with self-assembly features or fasteners locators.
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are easy to machine, although additions of fiberglass or carbon fiber can reduce the machinability. Plastics that are particularly soft and gummy may have machinability problems of their own.
341:
The objective is to design for lower cost. The cost is driven by time, so the design must minimize the time required to not just machine (remove the material), but also the set-up time of the
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DFM is essential for the successful and cost-effective production of advanced semiconductor devices. By proactively addressing manufacturability issues during the design stage, DFM leads to:
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design process, DFM leads to a set of design guidelines that attempt to ensure manufacturability. By doing so, probable production problems may be addressed during the design stage.
753:
Design for
Manufacturability & Concurrent Engineering: How to Design for Low Cost, Design in High Quality, Design for Lean Manufacture, and Design Quickly for Fast Production
196:
Foundries provide detailed design rules that specify minimum dimensions, spacing, and other geometrical constraints that must be adhered to for successful fabrication. DFM-aware
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conforming chart (CCC chart), which is applied in inspection and maintenance planning for systems where different types of inspection and maintenance are available.
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Typically, the law of diminishing returns presents itself at volumes of 100–300 because set-up times, custom tooling and fixturing can be amortized into the noise.
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214:, and deposition. By simulating how variations might affect specific design structures, designers can modify layouts to minimize sensitivity to these variations.
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Ideally, DFM guidelines take into account the processes and capabilities of the manufacturing industry. Therefore, DFM is constantly evolving.
61:
604:
Owusu-Boahen, Kwame; Han, Chang (Carl); Hsueh, Ching; Kim, Chulwoo (Jake); Vijayakumar, Arun; Devender, Fnu; Moreau, David J. (2021-02-22).
250:
Adding non-functional geometrical shapes to empty areas of a layout to improve pattern density and minimize local manufacturing variations.
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A thorough design rule check (DRC) and layout vs. schematic (LVS) verification is performed to ensure the design is ready for fabrication.
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Using statistical models to predict how design and process variations impact yield, allowing for informed design modification.
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606:"E-Beam detection of over-etch in semiconductor processing and how over-etch level is related to defect detection parameters"
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Adding extra transistors or circuit elements to critical paths, so if one element fails, the chip can still function.
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404:, and exotic alloys, they become much harder to machine and take much longer, thus being less manufacturable. Most
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During this stage, techniques like fill insertion and OPC are applied to the design for manufacturing optimization.
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Designers use DFM-aware tools that automatically check for rule violations and potential manufacturability issues.
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345:, NC programming, fixturing and many other activities that are dependent on the complexity and size of the part.
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can only approach the part from a single direction. One side must be machined at a time (called an operation or
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Verification processes include extensive DFM checks to ensure the design meets all manufacturing requirements.
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803:"Design for Inspection - Evaluating the Inspectability of Aerospace Components in the Early Stages of Design"
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A survey of the field of EDA. The above summary was derived, with permission, from Volume II, Chapter 19,
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A subset of design rules that are more conservative than standard rules, offering higher manufacturability.
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197:
1653:
1215:
738:"The #1 Killer to a Low Price CNC Machined Part - Parametric Manufacturing - CNC Machine Shop + Wire EDM"
525:
168:
Semiconductor Design for
Manufacturing (DFM) is a comprehensive set of principles and techniques used in
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only 30 minutes total machine time, then 7.5 hours is charged for just 30 minutes of machining.
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Modifying mask patterns to compensate for distortions that occur during the lithography process.
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component placement and soldering), such process is likely to be cheaper than doing so by hand.
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impact of these variations, improving yield and making chip manufacturing more cost-effective.
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455:(DFI) should complement and work in collaboration with design for manufacturability (DFM) and
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automatically check designs against these rules, flagging potential violations for correction.
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machine. Features that require smaller tools, regardless of L:D ratio, are more expensive.
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Six Sigma
Business Scorecard, Chapter 3 - Need for the Six Sigma Business Scorecard
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DFM techniques account for inherent variability in manufacturing processes such as
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Metrology, Inspection, and
Process Control for Semiconductor Manufacturing XXXV
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664:"Guide to CNC Machining Prototype & Production - Parametric Manufacturing"
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836:"Optimal design for inspection and maintenance policy based on the CCC chart"
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968:– DFM,DFA(Design for assembly checklist from Quick-teck PCB manufacturer
650:"How to Design Cheap Machined Parts and Why? - Parametric Manufacturing"
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While DFM is applicable to the design process, a similar concept called
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A common characteristic of additive manufacturing methods, such as
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Some common DFM techniques used in semiconductor design include:
132:(design for Six Sigma) is also practiced in many organizations.
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348:
921:, by Nicola Dragone, Carlo Guardiani, and Andrzej J. Strojwas.
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907:
Electronic Design
Automation For Integrated Circuits Handbook
587:"DFM helps manufacturers reduce cost while maintaining value"
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DFM is integrated throughout the semiconductor design flow:
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Stolt, Roland; Elgh, Frederik; Andersson, Petter (2017).
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Rule-based DFM analysis for electric discharge machining
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Rule-based DFM analysis for direct metal laser sintering
121:
tolerances, and secondary processing such as finishing.
603:
940:, by Robert Cisneros, Tecolote Research, Inc. (2008)
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135:
927:, by Michael Orshansky, Sani Nassif, Duane Boning
800:
919:Design for Manufacturability in the Nanometer Era
780:. New York: McGraw Hill Professional. p. 4.
384:The most easily machined types of metals include
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834:Chan, Ling-Yau; Wu, Shaomin (October 1, 2009).
158:
27:Designing products to facilitate manufacturing
1002:
349:Set-Up time of operations (flip of the part)
164:Semiconductor Design for Manufacturing (DFM)
608:. In Adan, Ofer; Robinson, John C. (eds.).
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995:
612:. Vol. 11611. SPIE. pp. 99–104.
546:Rule based DFM analysis for metal spinning
818:
111:) is the general engineering practice of
80:Learn how and when to remove this message
2526:Good Design Award (Museum of Modern Art)
750:
584:
551:Rule based DFM analysis for deep drawing
541:Rule based analysis of extrusion process
446:
353:Unless a 4th and/or 5th axis is used, a
91:
14:
2885:
938:Estimating Space ASICs Using SEER-IC/H
840:Computers & Industrial Engineering
833:
755:. Cambria, CA: CIM Press. p. 28.
2571:
2531:Good Design Award (Chicago Athenaeum)
2274:
1719:
1046:
990:
977:Design for Manufacturing and Assembly
972:Arc Design for Manufacturability Tips
775:
909:, by Lavagno, Martin, and Scheffer,
894:DFM: What is it and what will it do?
823:– via Elsevier Science Direct.
331:
29:
901:DFM: Magic Bullet or Marketing Hype
556:Rule based DFM analysis for forging
429:
24:
2572:
2475:American Institute of Graphic Arts
966:Design for manufacturing checklist
561:DFM analysis for stereolithography
25:
2929:
2485:Design and Industries Association
961:Why DFM/DFMA is Business Critical
954:
478:Design for additive manufacturing
472:Design for additive manufacturing
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411:
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136:For printed circuit boards (PCB)
96:Redesigned for manufacturability
60:has been specified. Please help
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324:Reduced risk of design re-spins
2480:Chartered Society of Designers
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263:Restricted Design Rules (RDR):
13:
1:
2551:Prince Philip Designers Prize
1194:Architectural lighting design
571:
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2908:Electronic design automation
2357:Electronic design automation
2340:Virtual home design software
1312:Automotive suspension design
820:10.1016/j.promfg.2017.07.244
511:Electronic design automation
336:
255:Optical Proximity Correction
159:For integrated circuits (IC)
101:Design for manufacturability
7:
1216:Environmental impact design
526:Statistical process control
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2495:International Forum Design
1865:Engineering design process
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1539:Stage/set lighting design
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1428:Hardware interface design
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1344:Hardware interface design
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1024:
903:(must fill request form).
896:(must fill request form).
852:10.1016/j.cie.2008.12.009
494:fused deposition modeling
327:Lower manufacturing costs
103:(also sometimes known as
2452:Industrial design rights
2440:Fashion design copyright
2352:Design quality indicator
1801:Creative problem-solving
1592:Electrical system design
1448:Sonic interaction design
1359:Photographic lens design
1233:Healthy community design
751:Anderson, David (2004).
297:Physical Implementation:
105:design for manufacturing
2648:New product development
2613:Enterprise architecture
2541:IF Product Design Award
2500:Design Research Society
2052:Reliability engineering
776:Gupta, Praveen (2006).
679:"Milling: Design Rules"
516:Reliability engineering
2918:Mechanical engineering
2104:Top-down and bottom-up
1453:User experience design
1354:Packaging and labeling
1327:Electric guitar design
1265:Landscape architecture
807:Procedia Manufacturing
585:Dolcemascolo, Darren.
483:Additive manufacturing
97:
2633:Innovation management
2516:European Design Award
2282:Intellectual property
2099:Theory of constraints
2062:Responsibility-driven
1902:For manufacturability
1806:Creativity techniques
1644:Nuclear weapon design
1458:User interface design
1322:Corrugated box design
1243:Interior architecture
942:Complete Presentation
453:design for inspection
447:Design for inspection
321:Faster time-to-market
95:
2678:Unintelligent design
2658:Philosophy of design
2372:Design specification
2325:Comprehensive layout
1897:For behaviour change
1870:Probabilistic design
1632:Power network design
1169:Visual merchandising
1126:Instructional design
1104:Postage stamp design
204:Process Variability:
62:improve this article
50:to meet Knowledge's
2903:Digital electronics
2598:Creative industries
2521:German Design Award
2430:Design infringement
2315:Architectural model
1654:Organization design
1649:Nucleic acid design
1597:Experimental design
1150:Traffic sign design
652:. 3 September 2016.
618:2021SPIE11611E..0NO
457:design for assembly
276:DFM and Design Flow
218:Yield Optimization:
185:Key Concepts in DFM
2663:Process simulation
2638:Intelligent design
1962:Intelligence-based
1957:Integrated topside
1887:Framework-oriented
1572:Behavioural design
1443:Information design
1121:Information design
947:2012-02-20 at the
899:Mentor Graphics -
892:Mentor Graphics -
697:has generic name (
626:10.1117/12.2584652
269:Yield Simulations:
170:integrated circuit
98:
2893:Industrial design
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2826:
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2593:Conceptual design
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2559:
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2546:James Dyson Award
2402:Website wireframe
2392:Technical drawing
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2114:Transgenerational
1855:Ecological design
1731:Activity-centered
1711:
1710:
1707:
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1689:Spacecraft design
1483:Public art design
1421:Video game design
1399:Experience design
1369:Production design
1349:Motorcycle design
1307:Automotive design
1211:Ecological design
1089:Film title design
635:978-1-5106-4055-9
332:For CNC machining
310:Importance of DFM
90:
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52:quality standards
43:This article may
18:Manufacturability
16:(Redirected from
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2446:Geschmacksmuster
2420:Community design
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2032:Process-centered
1828:Design–bid–build
1796:Cradle-to-cradle
1776:Concept-oriented
1717:
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1694:Strategic design
1664:Processor design
1639:Mechanism design
1607:Geometric design
1567:Algorithm design
1507:Jewellery design
1438:Immersive design
1332:Furniture design
1277:Landscape design
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2168:Value sensitive
2158:User innovation
2037:Public interest
2002:Object-oriented
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1684:Software design
1674:Research design
1627:Physical design
1582:Database design
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1524:Property design
1519:Game art design
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461:quality control
451:The concept of
449:
437:milling cutters
432:
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414:
398:stainless steel
382:
351:
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161:
138:
86:
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55:
39:
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28:
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15:
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11:
5:
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2688:Wicked problem
2685:
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2573:Related topics
2565:
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2490:Design Council
2487:
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2457:European Union
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2136:Usage-centered
2133:
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2129:Design for All
2121:
2116:
2111:
2109:Transformation
2106:
2101:
2096:
2091:
2090:
2089:
2079:
2074:
2069:
2064:
2059:
2057:Research-based
2054:
2049:
2044:
2039:
2034:
2029:
2024:
2022:Platform-based
2019:
2014:
2009:
2004:
1999:
1994:
1989:
1984:
1979:
1974:
1972:KISS principle
1969:
1964:
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1924:
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1909:
1904:
1899:
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1882:Fault-tolerant
1879:
1877:Error-tolerant
1874:
1873:
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1862:
1860:Energy neutral
1857:
1852:
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1816:Design fiction
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1699:Systems design
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1669:Protein design
1666:
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1659:Process design
1656:
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1622:Circuit design
1614:
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1550:
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1544:Textile design
1541:
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1531:
1526:
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1516:
1511:
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1502:Costume design
1497:Fashion design
1494:
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1379:Service design
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1374:Sensory design
1371:
1366:
1364:Product design
1361:
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1282:Spatial design
1279:
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1262:
1260:Keyline design
1257:
1256:
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1245:
1240:
1235:
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1226:Computer-aided
1218:
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1123:
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1094:Graphic design
1091:
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1084:Exhibit design
1081:
1076:
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1063:
1051:
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1039:
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985:
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979:
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955:External links
953:
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888:
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846:(3): 667–676.
826:
793:
786:
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762:978-1878072238
761:
743:
729:
713:"Design Guide"
704:
677:Inc., eFunda.
669:
666:. August 2016.
655:
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591:Reliable Plant
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58:cleanup reason
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2803:specification
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2731:
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2722:
2719:
2717:
2716:architectural
2714:
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2707:
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2683:Visualization
2681:
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2603:Cultural icon
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2468:Organizations
2466:
2458:
2455:
2454:
2453:
2450:
2448:
2447:
2443:
2441:
2438:
2436:
2435:Design patent
2433:
2431:
2428:
2426:
2425:Design around
2423:
2421:
2418:
2417:
2415:
2409:
2403:
2400:
2398:
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2285:Organizations
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2161:
2159:
2156:
2152:
2149:
2148:
2147:
2146:User-centered
2144:
2142:
2139:
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2134:
2130:
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2125:
2122:
2120:
2117:
2115:
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2110:
2107:
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2100:
2097:
2095:
2094:Tableless web
2092:
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2028:
2025:
2023:
2020:
2018:
2017:Participatory
2015:
2013:
2010:
2008:
2005:
2003:
2000:
1998:
1995:
1993:
1990:
1988:
1985:
1983:
1980:
1978:
1975:
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1968:
1965:
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1955:
1953:
1950:
1948:
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1943:
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1938:
1935:
1933:
1930:
1928:
1925:
1923:
1920:
1918:
1915:
1913:
1910:
1908:
1907:For Six Sigma
1905:
1903:
1900:
1898:
1895:
1893:
1890:
1888:
1885:
1883:
1880:
1878:
1875:
1871:
1868:
1867:
1866:
1863:
1861:
1858:
1856:
1853:
1851:
1850:Domain-driven
1848:
1846:
1843:
1839:
1838:architect-led
1836:
1835:
1834:
1831:
1829:
1826:
1824:
1821:
1817:
1814:
1813:
1812:
1809:
1807:
1804:
1802:
1799:
1797:
1794:
1792:
1789:
1787:
1784:
1782:
1781:Configuration
1779:
1777:
1774:
1772:
1769:
1767:
1764:
1762:
1759:
1757:
1754:
1752:
1749:
1747:
1746:Brainstorming
1744:
1742:
1739:
1737:
1734:
1732:
1729:
1728:
1725:
1718:
1714:
1700:
1697:
1695:
1692:
1690:
1687:
1685:
1682:
1680:
1679:Social design
1677:
1675:
1672:
1670:
1667:
1665:
1662:
1660:
1657:
1655:
1652:
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1647:
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1628:
1625:
1623:
1620:
1619:
1618:
1615:
1613:
1610:
1608:
1605:
1603:
1602:Filter design
1600:
1598:
1595:
1593:
1590:
1588:
1585:
1583:
1580:
1578:
1577:Boiler design
1575:
1573:
1570:
1568:
1565:
1564:
1562:
1560:
1551:
1545:
1542:
1540:
1537:
1535:
1532:
1530:
1529:Scenic design
1527:
1525:
1522:
1520:
1517:
1515:
1514:Floral design
1512:
1508:
1505:
1503:
1500:
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1246:
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1241:
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1236:
1234:
1231:
1227:
1224:
1223:
1222:
1221:Garden design
1219:
1217:
1214:
1212:
1209:
1205:
1204:Passive solar
1202:
1201:
1200:
1197:
1195:
1192:
1190:
1187:
1186:
1184:
1182:
1179:Environmental
1176:
1170:
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1153:
1151:
1147:
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1141:Retail design
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1110:
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1080:
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1059:Communication
1056:
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1027:
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1023:
1019:
1012:
1007:
1005:
1000:
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992:
989:
983:
980:
978:
975:
973:
970:
967:
964:
962:
959:
958:
950:
946:
943:
939:
936:
934:
933:0-387-30928-4
930:
926:
923:
920:
916:
915:0-8493-3096-3
912:
908:
905:
902:
898:
895:
891:
890:
877:
873:
869:
865:
861:
857:
853:
849:
845:
841:
837:
830:
821:
816:
813:: 1193–1199.
812:
808:
804:
797:
789:
787:9780071735117
783:
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772:
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454:
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418:
412:Material form
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387:
380:Material type
377:
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346:
344:
326:
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320:
318:Higher yields
317:
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291:Verification:
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126:
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119:
118:manufacturing
114:
110:
106:
102:
94:
84:
81:
73:
63:
59:
53:
49:
48:
41:
32:
31:
19:
2898:Design for X
2673:STEAM fields
2643:Lean startup
2628:Indie design
2444:
2411:Intellectual
2163:Value-driven
2141:Use-centered
2047:Regenerative
2027:Policy-based
1987:Mind mapping
1901:
1892:For assembly
1833:Design–build
1751:By committee
1736:Adaptive web
1534:Sound design
1492:glass design
1490: /
1475:applied arts
1416:Level design
1287:Urban design
1238:Hotel design
1189:Architecture
1164:Video design
1157: /
1148: /
1116:Illustration
1109:Print design
1079:Brand design
937:
924:
918:
906:
843:
839:
829:
810:
806:
796:
777:
771:
752:
746:
732:
720:. Retrieved
707:
672:
658:
644:
609:
599:
590:
580:
506:Design for X
491:
488:
481:
450:
441:
433:
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