Design for Manufacture: A Process, Not Just a Checkbox

This one’s for anyone getting close to production, or wondering why their last project hit a few unexpected speed bumps.

Let’s be honest, “Design for Manufacture” (DFM) doesn’t sound particularly exciting. It feels like something you’d throw in at the end of a project, maybe just before the files go off to a factory. But in reality? It’s one of the most important and most misunderstood phases in the entire design process.

If you’ve ever brought a product to market, you know this truth: designing something is one thing, but making it reliably, affordably, and at scale is another.

DFM isn’t just a checkbox before tooling. It’s a whole way of thinking. A methodical, behind-the-scenes phase of work that quietly determines whether your product gets made on time, on budget, and without surprises.

DFM isn’t about making a design look good on a screen. It’s about making sure it works in real-world factories, with real-world machines, materials, tolerances, and people.

It’s where we bridge the gap between design intent and manufacturing reality.

When it gets skipped or glossed over, things break. Literally. Timelines blow out. Costs creep up. And suddenly, the design that looked so perfect in CAD turns into a logistical headache on the factory floor.

So what are we actually doing when we talk “Design For Manufacture”?

We are making sure the design will hold up under the pressure of real-world manufacturing. Is this material going to behave the way we think it will? Is this geometry injection-mouldable, or will it trap gas or warp? Are we adding unnecessary complexity that’ll drive up tooling costs? Can it even be assembled? This stage is all about spotting risks early, when they’re still easy (and cheap) to fix.

The aim is to evolve the design to make it easier and more cost-efficient to produce. Sometimes that means tweaking the geometry to avoid undercuts. Sometimes it’s as simple as replacing a custom fastener with a standard one. We might relax a tolerance that doesn’t need to be as tight, or simplify a sub-assembly so it goes together faster on the line. Every small change adds up, and helps ensure your product can be made reliably, without headaches.

We also need to make sure everything is documented. Everything. In a simple, industry standard manner, that any worker can understand, even if they don’t speak English. Because generally, we are not there on the factory floor to explain things. So the drawings and accompanying documents and specifications have to be capable of explaining for us. It’s not a glamorous part of the process, but it’s essential. Vague or incomplete documentation is one of the biggest causes of manufacturing delays, especially when working with overseas suppliers. So I make sure what we send is tight, clear, and leaves no room for guesswork.

Finally, we test it. That might mean a final round of prototypes using production materials, or even a small pilot run to see how things go in the real world. It’s a chance to catch the little things you only notice when you’re holding the product in your hands, a part that doesn’t quite click into place, a thread that binds, or a tiny tolerance stack-up that suddenly matters.

The process takes time, but it saves so much time (and money) in the long run. No tooling rework. No last-minute part redesigns. No awkward emails to the factory asking why something doesn’t fit.

When I quote for a full product development project, the final DFM stage typically makes up around 30% of the total scope. It’s not just about smoothing the handoff to manufacturing, it’s about protecting the investment you’ve already made in your idea, and setting it up for success at scale. It’s non-negotiable and worth every cent.

So if you’re budgeting a new project, or you’ve got a prototype that’s working great and you’re starting to think about production, let’s talk. DFM is where everything gets real, and it’s one of my favourite parts of the process.

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Lucas Lastman

Freelance Industrial Designer Melbourne | Calm Under Pressure | CAD-to-Factory Translator

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