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David Willson

Technical Content Editor

About David

David is a mechanical engineer and technical writer with a BSME from Northeastern University and over 10 years of experience in product design and manufacturing. His work spans consumer electronics, medical devices, and aerospace applications, with experience in new product development (NPD), design for manufacturability (DFM), materials, quality, prototyping, and production. He brings deep expertise in processes such as injection molding, CNC machining, sheet metal fabrication, additive manufacturing, casting, and assembly.

All Articles by David Willson

Injection Molding Cycle Time: What Drives It and How to Reduce It

July 17, 2026

Material Traceability in Manufacturing: A Guide for Engineers and Procurement Teams

July 17, 2026

Bridge Production Manufacturing: What It Is, When to Use It, and How to Plan for It

July 10, 2026

Design for Testability (DFT): Building Products That Are Easier to Test and Validate

July 9, 2026

AS9100 and ISO 9001: Quality Standards For Aerospace Manufacturing

July 2, 2026

Robotic Arm Component Manufacturing: Process Selection and Domestic Sourcing Guide

July 2, 2026

Low-Volume Manufacturing: Processes, Costs, and Scaling Strategies

June 26, 2026

4-Axis CNC Machining: Capabilities, Applications, and Design Guidelines

June 26, 2026

Large-Format 3D Printing: Process, Design, and Sourcing Guide

June 24, 2026

eVTOL Aircraft Components: Custom vs. Standard Parts

June 22, 2026

Low-Pressure Die Casting (LPDC): Process, Benefits, and Design Guide

June 18, 2026

FictivMade Part 8: Final Part Unboxing & Testing

June 18, 2026

Large Part Injection Molding: Engineering Design & Sourcing Guide

June 12, 2026

Industrial Automation and Machinery MRO Strategy Guide

June 5, 2026

JIT vs. Safety Stock: Balancing Cash Flow and Uptime in MRO Inventory Strategy

June 5, 2026

How to Survive the Rush to Market for Humanoid Robotics: A Sourcing Strategy & Production Scaling Guide

June 5, 2026

Reverse Engineering for Industrial MRO Parts 

May 29, 2026

3-Axis CNC Machining Guide: Capabilities, Limitations, and Use Cases

May 29, 2026

Manufacturing Continuity and Reducing Risk During Production Scale-Up

May 26, 2026

Semiconductor Equipment Manufacturing for Precision Hardware Systems

May 22, 2026

Custom vs. Configurable Components: How Engineers Choose the Right Sourcing Strategy

May 22, 2026

Scaling CNC to Casting Guide

May 22, 2026

Prototyping Cost: What Drives Pricing Across Manufacturing Processes

May 15, 2026

Gravity Casting (Permanent Mold Casting): Process, Benefits, and When to Use It

May 14, 2026

Metal Casting Defects: Types, Causes, and How to Prevent Them

May 13, 2026

MRO Automation: How Smart Inventory Systems Are Transforming Manufacturing Supply Chains

May 7, 2026

Data Center Infrastructure Design: Custom Manufacturing and Off-the-Shelf Components for AI and Cloud Hardware

May 6, 2026

Stage Gate Product Development: A Guide to Process Models and Best Practices

May 5, 2026

Cleanroom Manufacturing: ISO Standards, Applications, and Design Guidelines

May 5, 2026

Prototyping Lead Time: Process Timelines and How to Reduce Delays

May 1, 2026

Aerospace Materials and Finishes: Component Design for Spacecraft and Satellites

April 24, 2026

What are MRO Parts? Definition, Examples, and Sourcing Strategies

April 24, 2026

Simulation vs Reality in Hardware Development: Prototyping, Validation, and Iteration

April 22, 2026

CNC vs Die Casting Qualification Scorecard 

April 6, 2026

The CNC Periodic Table: A Visual Guide to the Core Elements of Machining

April 6, 2026

High-Strength CNC Machining Materials: Selection, Trade-offs, and Design Considerations

March 31, 2026

Overmolding Materials Guide: Material Bond Compatibility

March 31, 2026

Manufacturing Process Cost & Lead Time Comparison 

March 31, 2026

Material Selection for Medical Device Manufacturing: The Best Medical Grade and Biocompatible Options

March 25, 2026

Rugged Hardware Design for Harsh Environments: Materials, Sealing, and Reliability Strategies

March 25, 2026

Environmental Resistance of Materials: Chemical, Thermal & Corrosion Performance Compared

March 20, 2026

Fictiv Launches Instant Online Quoting for Injection Molding Parts

March 17, 2026

The 7 Most Common Tolerance Mistakes Mechanical Engineers Make—and How to Fix Them in Minutes

February 27, 2026

How to Single Source Standard and Custom Parts From One Manufacturing Partner for BOM Consolidation

February 26, 2026

The Top 10 Schedule Levers in Product Development (and When to Use Each One)

February 26, 2026

How to Build a BOM Strategically and Cost Down Your Part List

February 25, 2026

Progressive Sheet Metal Stamping: When to Use It for Complex, High-Volume Parts

February 24, 2026

Manufacturing for Robotics: Processes, Strategy, and Component Selection

February 15, 2026

Product Assembly Guide: DFA and Joining Methods

February 8, 2026

Energy Storage Systems (ESS): Types, Design Considerations, and Manufacturing Challenges

February 4, 2026

Jetting Defects in Injection Molding: Causes, Identification, and Prevention

February 4, 2026

Laser Welding: Process, Advantages, Applications, and Design Guidelines

February 3, 2026

Quality Control in Manufacturing: Processes, Standards, and Best Practices for Reliable Production

January 27, 2026

Design for Excellence (DFX) in Product Development: How DFM, DFA, and More Improve Manufacturing Efficiency

January 26, 2026

Design for Serviceability: Engineering Products for Maintenance and Repair

January 21, 2026

Ejection Systems in Injection Molding: Design, Types, and Best Practices 

December 24, 2025

Composite Layup: A Practical Guide to the Manufacturing of High-Performance Composites

December 23, 2025

The Top AI Tools Helping Mechanical Engineers in Product Design and Development

December 23, 2025

Metal Stamping Guide to Processes, Tooling, and Design for Manufacturability

December 23, 2025

Design of Experiments (DOE) in Engineering: A Practical Guide for Product Optimization

December 23, 2025

AI in Digital Manufacturing: How Artificial Intelligence Improves Production Efficiency and Quality

December 23, 2025

Sheet Metal Welding Design Guide

December 15, 2025

Mechanical Fasteners: A Complete Hardware Guide for Engineers and Product Designers

December 12, 2025

The Future of Climate Tech Manufacturing: Trends, Challenges, and Emerging Solutions

December 9, 2025

Living Hinge Design: How to Design a Living Hinge

December 3, 2025

First Article Inspection (FAI): The Guide for Engineers and Manufacturers

December 2, 2025

Gas-Assisted Injection Molding: A Complete Guide 

November 24, 2025

Adhesives for Assembly in Manufacturing: A Guide to Bonding Metal, Polymer, and Composite Components

November 21, 2025

Tabs and Slots for Sheet Metal Part Design

November 20, 2025

3D Printing With TPU: A Practical Guide for Engineers and Product Designers

November 14, 2025

Flexible Materials for 3D Printing: A Selection Guide to Elastomeric Filaments for Soft Components 

November 14, 2025

Metal Assemblies: Fabrication Methods, Joining Techniques, and Design Guidelines

October 29, 2025

Warping in Injection Molding: Causes, Prevention, and Troubleshooting Guide

October 21, 2025

Heat Staking in Product Design: Process, Geometry Guidelines, and Applications

October 20, 2025

How to Design Snap Fit Components

October 17, 2025

Design for Manufacturing Terms: Definitions and Examples

October 15, 2025

Ultrasonic Welding in Product Design: Principles, Benefits, and Design Guidelines

October 14, 2025

Micro Injection Molding: Materials, Design, Tolerances & Applications

October 6, 2025

Six Sigma in Manufacturing: Principles, DMAIC Tools, and Applications

October 2, 2025

Sheet Metal Fasteners and Self-Clinching Hardware: Types, Installation, and Best Practices

October 2, 2025

Rapid Prototyping: A Guide on the Methods for Fast Product Development

October 1, 2025

Injection Molding Process Parameters: How to Adjust for Quality, Efficiency, and Defect Prevention

October 1, 2025

Rapid Prototyping with 3D Printing: Methods, Uses & Solutions

September 23, 2025

AI Tools for Mechanical Engineering: How They Can Fall Short

September 16, 2025

FictivMade: Designing a Plastic Hinge with a Snap-Fit Pin

September 15, 2025

Design for Sustainability (DFS): A Guide for Engineering More Eco-Friendly Products

September 8, 2025

Design for Cost (DFC) and Design to Cost (DTC): Balancing Performance and Affordability in Product Design

September 4, 2025

Design for Reliability (DFR): Engineering Quality Products That Last

September 4, 2025

5‑Axis CNC Machining: Precision Capabilities for Complex Parts

August 29, 2025

Design for Manufacturing (DFM): A Guide for Smarter and More Efficient Production

August 29, 2025

Selecting the Right Material for Your Injection Molding Project

August 20, 2025

FictivMade: Mold Trials & Revisions for Production-Ready Injection Molds

August 15, 2025

Product Requirements Document (PRD): Purpose & Best Practices

August 15, 2025

FictivMade Part 5: Inside the Injection Mold Tooling Process 

August 7, 2025

Torlon® (PAI): A High-Performance Plastic With Advanced Material Properties

July 31, 2025

Soft Polymers for Product Design: Comparing Flexible Materials

July 31, 2025

POM(Acetal/Delrin®) Plastic: Properties, Advantages, and Material Comparisons

July 30, 2025

Boring vs. Drilling vs. Reaming: A Guide to Precision Hole Machining

July 18, 2025

Plastic Fillers: Glass, Carbon, and Mineral-Filled Thermoplastics for Engineering Applications

July 18, 2025

FictivMade: Detailed DFM Analysis

July 15, 2025

Design for Manufacturing and Assembly (DFMA): Principles, Best Practices, and Real-World Examples

July 1, 2025

Humanoid Robots in Manufacturing: Transforming Industrial Automation

July 1, 2025

Investment Casting Explained: Process, Benefits, and Applications

June 30, 2025

Laser Cutting for Precision Metal Fabrication: How the Process Works, Best Materials, and Design Guidelines

June 24, 2025

Short Shot Defects in Injection Molding: Causes, Identification, and Solutions

June 23, 2025

FictivMade: Quoting on Our Digital Manufacturing Platform

June 21, 2025

Insert Molding: A Complete Guide to Integrated Part Injection Molding

June 13, 2025

Digital Transformation in the Manufacturing Industry

June 13, 2025

Family Tooling in Injection Molding: A Guide to Multi-part Production

June 13, 2025

GD&T Basics with Examples: A Guide to Geometric Dimensioning and Tolerancing

June 6, 2025

High-Pressure Die Casting: Process Overview, Applications, and Material Considerations​

June 5, 2025

Large CNC Machining: Precision Manufacturing for Oversized Components​

May 30, 2025

Product Development Process: Design Phase of a Multi-Tool Phone Stand From Concept to Prototype

May 21, 2025

Liquid Silicone Rubber (LSR) Injection Molding: Process, Benefits, and Applications​

May 19, 2025

OEM vs. ODM vs. JDM: Key Manufacturing Models Explained for Scalable Product Development

May 19, 2025

PPAP: Production Part Approval Process Guide for Manufacturing

May 19, 2025

Rapid Injection Molding Guide: Process, Materials, and Benefits

May 13, 2025

Understanding the Types of Fit in Engineering: Clearance, Transition, and Interference

May 12, 2025

Developing Effective Manufacturing Strategies: Key Approaches and Best Practices​

May 8, 2025

Tariffs and Import Duties 101: A Guide to Managing Global Trade Costs

April 29, 2025

Sheet Metal Prototyping: Processes, Materials, Applications, and Benefits

April 29, 2025

Metal Parts Manufacturing: A Comprehensive Guide to Processes, Applications, and Industry Uses

April 28, 2025

Optimizing Manufacturing Supply Chain Management: Strategies for Efficiency and Resilience

April 22, 2025

Sustainable Plastics Manufacturing: Advancements in Eco-Friendly Injection Molding

April 22, 2025

Understanding Pad Printing: Process, Applications, and Comparisons With Screen and UV Printing

April 21, 2025

Medical Device Injection Molding: A Complete Guide

April 15, 2025

CNC vs. 3D Printing for Prototypes – Which Is Best for Your Project?

April 15, 2025

Fictiv-Made Part 2: Design for Injection Molding and Overmolding

April 14, 2025

Lean Manufacturing in Production Processes 

April 14, 2025

Just-in-Time Manufacturing: Streamlining Production for Optimal Efficiency​

April 14, 2025

High-Mix Low-Volume (HMLV) Manufacturing: Production and Supply Chain Strategies 

April 13, 2025

New Product Introduction (NPI) for Manufacturing: Tips for Team Alignment

April 13, 2025

Powder Coating: Process, Benefits, and Industry Applications

April 13, 2025

High Volume 3D Printing for Mass Production: Where It Works and Where It Falls Short

April 11, 2025

The Best 3D Printers in 2025 – A Complete Guide for Every Need

April 11, 2025

3D Printed Molds: A Cost-Effective Alternative for Low-Volume Production and Prototyping

April 11, 2025

CNC Machining Coolants and Cutting Fluids: Types, Benefits, and Best Practices

April 11, 2025

Copper in Manufacturing: Properties, Types, Processes, and Industry Applications

April 9, 2025

5 Signs It’s Time To Upgrade Your Manufacturing Strategy – And How Digital Manufacturing Can Help

April 1, 2025

The Impact of AI in Mechanical Engineering

March 20, 2025

Single-Minute Exchange of Die (SMED): Optimizing Injection Molding Efficiency

February 26, 2025

Multi-Cavity Injection Molding for Higher-Volume Production Efficiency

February 23, 2025

Die Casting: Overview, Materials, Process, & Applications

February 3, 2025

The Future of Injection Molding: 7 Trends to Watch in 2025 and Beyond

January 30, 2025

What is Nearshoring and Why are Companies Moving Their Manufacturing Closer to Home?

January 10, 2025

Advanced Materials Guide for Injection Molding

December 18, 2024

Tips to Reduce Injection Molding Costs

December 13, 2024

Chem Film, Anodizing, and Black Oxide: Which Conversion Coating is Right for Your Project?

November 25, 2024

Injection Molding Tooling: The Complete Guide

November 20, 2024

CNC Stepover Guide: Understanding Its Impact on Surface Finish and Machining Efficiency

October 23, 2024

CNC Machining Outsourcing: Fictiv’s Detailed Guide

October 8, 2024

APQP: Advanced Product Quality Planning Explained

September 6, 2024

The 10 Most Common Injection Molding Defects and How to Fix Them 

August 29, 2024

Plastic Joining Methods: A Guide to Mechanical Fastener Options From Snap Fits to Adhesives

October 18, 2023

Casting vs. CNC Machining: How to Choose the Right Process for Your Part?

September 29, 2022

Prototype Testing Guide: Validating Hardware Engineering Designs

November 3, 2017

Options for 3D Printing Clear Parts

August 26, 2015

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