At FMI Building Innovation, we believe great design doesn’t stop at the drawing board - it flows seamlessly through manufacturing, assembly, and ultimately, the performance of a finished building. That philosophy has a name: Design for Manufacture and Assembly (DfMA).
Though the term is relatively recent, the principles behind it are not. History shows us countless examples of design driving efficiency downstream. One of the most striking is London’s Crystal Palace, built in 1851 (see image above). Joseph Paxton’s use of modular, standardised components enabled a vast, complex structure to be erected in just eight months - a powerful early example of DfMA at work.
The principles of DfMA
At its heart, DfMA brings two disciplines together: Design for Manufacture (DfM) and Design for Assembly (DfA). The goal is simple but transformative - design products so they’re easier, faster, and more cost-effective to produce and assemble without compromising performance.
Key principles include:
Standardisation - using common lengths, components, and processes to reduce waste, simplify stockholding, and improve reliability.
Modularisation - creating building blocks that fit together across product families, cutting bespoke tooling costs and simplifying repair or replacement.
Simplicity - reducing parts to the minimum needed for function, cutting assembly errors, and boosting consistency.
The benefits are clear: lower costs, faster production, higher quality, and more resilient supply chains.
Applying DfMA at FMI Building Innovation
At FMIBI, DfMA isn’t a buzzword - it’s how we work. We start with the end goal in mind, then design backwards to ensure products can be manufactured efficiently, assembled consistently, and delivered at scale.
Recent examples include:
Automation in component production - robotics now manufacture high-precision parts like window friction stays, improving safety and repeatability while reducing defects.
Smarter jointing systems - innovations such as our Touxlock™ corner joints simplify assembly, doubling fabricator speed while improving weather resistance.
Re-engineered doors - by replacing complex extruded assemblies with laminated designs, we’ve reduced parts, cut production time, and delivered stronger, lighter doors.
These changes may look small in isolation, but together they represent a systematic shift - one that helps fabricators deliver faster, with fewer errors, and with products that consistently perform.
Why it matters more than ever
The building sector faces growing pressure: stricter energy codes, tighter timelines, and the need to reduce waste and carbon. DfMA provides a proven framework to respond. By standardising, modularising, and simplifying, we can deliver products that support affordable, energy-efficient, and sustainable buildings - while making life easier for our fabricator network.
As our Managing Director Warren Lewis puts it, “We’ve always started with the end in mind. What we didn’t know was that the world calls this DfMA. For us, it’s just common sense.”
Looking ahead
DfMA continues to evolve. Advances in robotics, automation, 3D printing, and even generative AI are opening new possibilities. At FMIBI, we’re already exploring how these technologies can further streamline our processes and create even greater value for our partners and their customers.
One thing won’t change: our commitment to innovation and excellence. With DfMA guiding our approach, we’ll continue to help businesses get ahead of the curve and deliver buildings that perform better - for people and for the planet.
