3.1 The Virtual Build – DFM and Strategic Sourcing

The most expensive defects are those created before manufacturing begins. The "Virtual Build" phase is a risk mitigation process where the digital design is stress-tested against the physical realities of the factory and the market.

Design for Manufacturing (DFM)

DFM is the engineering equivalent of a code review. Dannie engineers analyze the client’s CAD files to identify "bugs" in the physical layout.

• Geometry Checks: Ensuring solder pads are large enough to hold the part but small enough to prevent the part from floating away.
• Spacing Checks: Verifying that components are not placed so closely that the robotic nozzles collide during assembly.
• Outcome: A "DFM Report" is generated, highlighting risks. Resolving these issues in the file stage costs $0; resolving them on the line costs thousands in scrap.

Strategic Sourcing

A valid design is useless if the parts cannot be bought.

• Obsolescence Management: Checking if any specified chips are "End of Life" (EOL) or "Not Recommended for New Design" (NRND).
• Supply Chain Validation: Dannie’s procurement team utilizes a database of 400,000+ verified components to secure stock from authorized distributors, mitigating the risk of counterfeit parts entering the supply chain from the grey market.

Final Checklist

Activity	Goal	Deliverable
DFM Check	Validate Physical Layout	DFM Report / EQ List
BOM Scrub	Validate Part Availability	Stock Status / Pricing
AVL Check	Validate Alternate Parts	Approved Vendor List
Data Freeze	Lock Configuration	Golden Data Pack