In today’s rapidly evolving manufacturing landscape, start-ups and small to medium-sized businesses (SMBs) face numerous product development challenges. As product complexity escalates, traditional manufacturing methods are proving inadequate. A new approach is essential to staying competitive. Model-based definition (MBD) is emerging as a transformative strategy that reshapes how companies create, document, and manufacture products.
Robust and accessible documentation is essential
Efficient product development and manufacturing processes rely on clear, robust design documentation. Historically, manufacturing start-ups and SMBs have relied heavily on 2D engineering drawings to document detailed product and manufacturing information (PMI)—data that defines and communicates product specifications. As product complexity increases, however, such reliance on 2D renderings can cause problems. The conversion from 2D drawings to accurate 3D models, for example, frequently leads to errors that result in costly rework downstream. Additionally, 2D drawings limit collaboration and traceability across the development lifecycle, as they typically exist separately from 3D computer-aided design (CAD) models. When design changes occur, teams must update the 3D models manually, risking mistakes that require rework to fix. This disconnect can lead to extra costs, delays, and extended development cycles, posing significant challenges for start-ups and SMBs that may lack the resources of their larger or more well-established counterparts.
Traditional methods are prone to errors
The limitations of traditional 2D drawings are evident in several key areas. Creating fully annotated 2D drawings is labor-intensive and time-consuming, often taking longer than developing the corresponding 3D model. This inefficiency raises development costs and extends lead times, undermining the competitiveness of smaller organizations. Furthermore, the number of professionals who possess the skills needed to extrapolate 3D shapes from 2D engineering drawings is dwindling, and this diminishing expertise exacerbates the problem. The likelihood of errors only increases when transferring PMI from 2D to 3D models, and missing or inaccurate dimensions can lead to costly redesigns and rework efforts if discovered late in the process. The lack of a cohesive digital thread makes it challenging to trace changes across the product lifecycle, hindering version control and collaboration.
In addition, 2D drawings often fail to capture the full complexity of modern designs, leading to misinterpretations and manufacturing errors. They also limit stakeholders’ ability to fully visualize the design and perform advanced simulations and analyses, all of which is crucial for optimizing product performance and manufacturability. The static nature of 2D drawings makes it difficult to incorporate real-time design changes, resulting in outdated documentation and potential miscommunication between teams.
Compliance issues may also arise in industries like automotive and aerospace, where accurate PMI is contractually mandated. The reliance on 2D drawings can complicate regulatory approvals and slow down certification processes, further impacting time to market for start-ups and SMBs.
Model-based definition unlocks greater efficiency
MBD addresses the drawbacks of 2D drawings by using comprehensive 3D models as the primary means of documenting and sharing PMI. This approach provides all stakeholders with a single source of truth that captures everything from design intent to materials and manufacturing instructions. This comprehensive 3D model includes the dimensions, tolerances, and materials typically represented in 2D drawings, as well as annotations, service bill of materials (BOM) software tables, specifications, and notes. In its most powerful form, an MBD model can seamlessly capture and communicate data from initial design through to CNC machining or 3D-printing-based manufacturing.
Modern MBD solutions offer intelligent assistance that simplifies complex geometric tolerancing tasks within the CAD environment, improving model accuracy and accelerating the design process. Today’s solutions can also support concurrent engineering practices, enabling cross-functional teams to collaborate effectively from the earliest stages of design and identify and resolve potential issues early in the development process. Cloud-based MBD solutions are particularly valuable in this regard, as they enable stakeholders to access and update models from anywhere, ensuring everyone works with the most current information. This approach saves time and resources while enhancing internal accountability through complete records of design changes and annotations.
Additionally, MBD significantly reduces documentation time and minimizes the risk of errors that can occur when translating information between 2D and 3D formats. It facilitates easier design iterations and updates, as changes to the 3D model automatically propagate to all associated views and annotations. MBD enhances manufacturing processes by providing clearer representations of complex geometries, reducing misinterpretations on the shop floor and improving product quality. As start-ups and SMBs leverage the advantages of MBD, they can streamline their development processes, ultimately driving better outcomes in less time while positioning themselves to integrate emerging technologies, such as augmented reality (AR) and artificial intelligence (AI).
Conclusion
As product complexity continues to rise, embracing MBD becomes crucial for start-ups and SMBs in the manufacturing sector. The risks posed by miscommunication and inaccurate PMI are simply too costly to ignore, especially for organizations with limited resources. By adopting MBD practices, these organizations can accelerate their product development processes, reduce documentation burdens, and optimize cross-functional teamwork. Ultimately, MBD empowers smaller manufacturers to achieve better outcomes in less time, positioning them for success in an increasingly complex and fast-paced industry.
To learn more how startups and SMBs can beneficiate from a a model-base definition (MBD) approach, get the e-book Maximizing Efficiency: Model-Based Definition for Manufacturing Startups and SMBs
Disclaimer: This post was written by Lifecycle Insights and may not reflect the official position of Dassault Systèmes.