DBC-002

Pack: G_BASELINE Severity: major

Avoid sharp internal corners; use generous radii so material and tools can move smoothly

Rule Card

Field	Value
Pack	G_BASELINE — DFM Baseline Codex
Title	Avoid sharp internal corners; use generous radii so material and tools can move smoothly
Severity	major
Check logic	Deterministic
Applies to	CAD part, CAD pocket feature, CAD wall feature
Inputs required	radii_set, geometry_features
Fix template	Replace sharp corners with larger radii or relief geometry that matches the manufacturing route.

Short Description

Sharp corners concentrate stress, weaken tools, disrupt material flow, and create difficult-to-machine or difficult-to-mold geometry. A larger inside radius improves both tool life and part strength.

When It Applies

This rule belongs to G_BASELINE (Shared across multiple manufacturing routes) and targets CAD part, CAD pocket feature, CAD wall feature.

Evidence Profile

Input	Category
radii_set	Geometry
geometry_features	Geometry

References

Reference	Type	Title
REF-BOOK-DFM-SUCCESS	book	A Definitive Guide to Design for Manufacturing Success
REF-BOOK-DFM-INJECTION	book	Design for Manufacturing Analysis: Injection Molding Review Guide

Compiled Threshold Metadata

Field	Value
molded_corner_radius_to_wall_min	0.5
machining_guidance	largest practical internal radius

Sources

• D:\02_Code\36_RapidDraft_DFMBenchmark_ExpertMode\server\dfm\manifest.json
• D:\02_Code\36_RapidDraft_DFMBenchmark_ExpertMode\server\dfm\rule_library.json
• D:\02_Code\36_RapidDraft_DFMBenchmark_ExpertMode\server\dfm\references.json
• D:\02_Code\36_RapidDraft_DFMBenchmark_ExpertMode\server\dfm\process_classifier.json
• D:\02_Code\36_RapidDraft_DFMBenchmark_ExpertMode\server\dfm\overlays.json
• D:\02_Code\36_RapidDraft_DFMBenchmark_ExpertMode\server\dfm\roles.json
• D:\02_Code\36_RapidDraft_DFMBenchmark_ExpertMode\server\dfm\report_templates.json
• D:\02_Code\36_RapidDraft_DFMBenchmark_ExpertMode\server\dfm\ui_bindings.json