Expanding the Horizons of Design for Manufacture and Assembly (DfMA) in Architecture: DfMA and the Design Process
- Mahdiar Gh
- Jan 12
- 3 min read
Updated: Jan 14
DfMA Design Mindset
Design for Manufacture and Assembly (DfMA) is more than a methodology—it’s a mindset that extends beyond understanding how a building is constructed. It encompasses the entire supply chain and manufacturing processes, pushing the boundaries of good design and production practices. While it doesn’t alter the fundamentals of design, it amplifies them, fostering a holistic approach to efficiency, sustainability, and innovation.
To address the rise of prefabrication and the increasing complexity of building systems, as well as societal, financial, and environmental challenges, designers must:
Build product-oriented knowledge bases to adapt to specific project needs.
Develop digital tools that support project-by-project design optimization.
Identify optimal solutions that balance trade-offs, requirements, and performance goals.
Knowledge-Based Engineering (KBE) applications offer promising solutions by providing digital product models that inform designers about manufacturability and expected performance. However, current digital tools often focus on single disciplines, neglecting the integration of manufacturing stages. DfMA encourages a more cohesive approach by creating standardized, repeatable components—a "kit of parts"—that meet common standards for assembly and offer flexibility to meet diverse user needs. This "platform DfMA" approach empowers the supply chain to invest confidently in systems and facilities tailored to these standards.
[Research at XOIA Studio: https://www.xoia.ca/services-research]
Design Workflow and Delivery
The architectural design workflow for DfMA integrates efficiency and cost-effectiveness into every project stage, impacting feasibility, sustainability, and project outcomes. Here’s how it unfolds:
1. Pre-Design Phase
DfMA considerations begin with site appraisals and the client’s project brief. Early assessments focus on the feasibility of modular construction and the potential for reusing previous DfMA strategies, especially for clients managing multiple projects. Client-driven criteria can evaluate the design team’s ability to innovate within the DfMA framework.
2. Conceptual Design
In this phase, architects:
Collaborate closely with clients to understand project requirements.
Integrate principles of modularization, standardization, and prefabrication into preliminary designs.
3. Schematic Design
Key DfMA aspects must be incorporated during schematic design, including:
Choosing between grid systems or volumetric modular structures.
Assessing site-specific constraints, budget, and supplier capabilities.
Exploring repeatable DfMA processes for optimization and improvement.
A well-executed schematic design incorporates standardized components without stifling creativity. Utilizing tools like Building Information Modeling (BIM), design teams can automate repetitive tasks and focus on bespoke elements that add value.
4. Design Development and Construction Drawings
During design development:
Collaboration with contractors, suppliers, and manufacturers is essential.
Prototypes of factory-manufactured components help refine designs and address on-site challenges.
Coordination through BIM models ensures alignment across disciplines, reducing costs and duplication.
Detailed construction drawings evolve into fabrication models that integrate design intent and practical assembly considerations. This minimizes rework and streamlines production.
5. Construction Phase
Incorporating DfMA transforms construction sites into efficient hubs of activity:
Components arrive as pre-packaged “fit-out kits,” including prefabricated bathrooms, wiring looms, and service units.
On-site customization is minimized, enabling faster and more precise assembly.
6. Occupancy and Post-Occupancy
In this stage, detailed asset information is recorded for maintenance and future use. This includes DfMA-specific data, such as:
Disassembly instructions for end-of-life considerations.
Real-time performance feedback to inform future projects.
A robust feedback loop between post-occupancy and pre-design stages optimizes future workflows and enhances project outcomes throughout the building lifecycle.
Digital Workflows and Feedback Loops
The architectural design and production process for DfMA functions as a bi-directional continuum. Multiple feedback loops facilitate negotiation between design intentions and practical influences, including:
Fabrication constraints.
Material properties.
Financial pressures.
Contextual considerations.
To achieve this, advanced digital platforms must:
Seamlessly integrate design and fabrication workflows.
Eliminate traditional construction drawings by directly communicating instructions through algorithm-driven workflows.
Reduce friction in information transfer between platforms.
BIM and DfMA both rely on standardized information and processes. While BIM provides a foundation, further development of DfMA-specific workflows is essential to:
Define the level of detail required for prefabrication.
Standardize feedback loops and decision tracking for continuous improvement.
The Future of DfMA in Architecture
To fully realize DfMA’s potential, the industry must embrace its principles at every level. This includes:
Developing advanced software platforms that bridge design and fabrication.
Formalizing international standards for DfMA workflows and information exchanges.
Promoting education and collaboration across disciplines to foster innovation.
By aligning design intent with manufacturing precision, DfMA offers a pathway to revolutionize architecture, addressing global challenges while unlocking unprecedented opportunities for creativity, efficiency, and sustainability.
Acknowledgment
This blog post is informed by research conducted as part of the Researcher-in-Residence program at Perkins and Will. Special thanks to the Vancouver and Calgary studios, my co-researcher Elton Gjata, and the advisory committee (Yehia Madkour, Kathy Wardle, Andrew TsayJacobs, Adrian Watson) for their invaluable contributions.
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