Silicone Molding Press - Saint-Gobain Medical
Expert Interview: DFM Medical Molding
Written by
Kelsey Becker
Charles Klann
Published on
05 March 2026
Reading time
3 minutes
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Article contributed by
Kelsey Becker
Kelsey Becker
Chuck Klann
Charles Klann
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Expert Interview: The Critical Role of DFM in Medical Component Development

Insights From a Veteran Engineer on Effective DFM

Design for Manufacturability (DFM) is one of the most pivotal elements in ensuring the success of any medical component. From selecting materials to shaping tooling strategy to preparing for scalable production, early and thoughtful DFM planning can dramatically accelerate development timelines and reduce risk.

To explore what DFM really looks like in practice, we sat down with Chuck Klann, an engineering veteran with more than 30 years experience at Saint‑Gobain Medical. With deep expertise in application engineering, prototyping, and manufacturing scale‑up, Chuck has a unique vantage point into how early collaboration influences downstream success.

What are the most common challenges you see related to DFM?

A: Material selection is the first big challenge, especially with silicone. Every grade has unique physical properties, so it must match the performance needed for the application.

After that, we look at the physical design of the part: wall thicknesses, geometry, and interaction with tooling. Both material and design must align with the manufacturing process to ensure long-term consistency and accuracy.

Why is early stage involvement so critical to product success?

A: Early collaboration ensures we create a tooling strategy that supports sustainable, long‑term production. When we review feasibility early, particularly things like wall thickness, we reduce risk downstream.

It sets the foundation for a consistent, accurate process that meets customer needs year after year.

Chuck Klann

DFM isn’t just about making something moldable; it’s about understanding the full lifecycle from design to validation to long‑term manufacturing. 

Chuck Klann

Can you share an example where early collaboration helped prevent downstream issues?

A: Thin‑wall pressure membranes are a great example. These often require gating extremely close to the membrane, or even directly on it, to ensure proper fill.

Without early conversations, that gating choice could compromise the final device performance. Early collaboration lets us balance manufacturing realities with functional requirements, allowing us to recommend design adjustments that protect performance while enabling smooth production.

How does thoughtful DFM support rapid prototyping and faster design iterations?

A: Once we align with the customer on recommendations, including gating, parting lines, surface finish, and tool design, we quickly create functional prototype parts they can test in their device.

Prototyping lets us see:

  • How the part fills
  • How it functions
  • Where potential issues lie
  • Part removal, part ejection

Some programs require multiple iterations; I’ve worked on projects with eight or nine prototype rounds before reaching the final optimized design.
This iterative approach gives customers confidence and helps us build a strong path toward a robust production tool.

Is there anything else customers should understand about DFM?

A: One area gaining importance is tolerance validation. We often produce “high” and “low” samples representing the extremes of a critical tolerance so customers can validate performance across the full production range.

This ensures:

  • The device performs consistently
  • The customer understands the full tolerance window
  • Production launches with lower risk

DFM isn’t just about making something moldable, it’s about understanding the full lifecycle from design to validation to long‑term manufacturing.

Saint-Gobain molding machine with employee in background

Key Takeaways on DFM for Medical Molding

DFM is the foundation of successful medical molding. Through early collaboration, material expertise, and rapid prototyping, Saint‑Gobain Medical helps customers refine designs efficiently and scale confidently.

Chuck’s insights highlight a simple truth: engaging early and iterating often leads to better designs, faster timelines, and more reliable manufacturing outcomes.

If you’re exploring a new silicone or thermoplastic component, our engineering team is ready to collaborate from the earliest stages to ensure a smooth, scalable development process.

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