Bridging the Gap Between CAD and the Factory Floor.

Design for Manufacture

Upside-down wooden chair with broken legs and a glass top table on a white background.

From Concept to Production—Without Compromise

At FormaSharp, we don’t just design products—we visualize them for reality. Our Design for Manufacture (DFM) approach ensures that every concept we create is optimized for the manufacturing process it’s intended for by working with your manufacturer. Whether you're prototyping a new idea or preparing for full-scale production, our designs are built to perform, built to last, and built to be made.

We understand the nuances of various manufacturing methods and integrate those requirements directly into the design phase. This means fewer revisions, lower production costs, and faster time-to-market.

3D printer on a wooden table printing small blue objects.
Close-up of a smartphone screen displaying the word 'design' and its definition, with icons for WhatsApp and messaging apps at the top.

Our Value Proposition

  • Production-Ready Designs: Every model is created with manufacturing constraints in mind.

  • Reduced Rework & Waste: Minimized design iterations and material inefficiencies.

  • Cross-Process Expertise: We tailor designs to suit specific fabrication methods.

  • Seamless Handoff: Clear documentation and CAD files ready for machinists, molders, and fabricators.

Industrial factory with orange robotic arms and conveyor system for manufacturing.
Five purple glass perfume bottles with gold caps arranged in a staggered line on a reflective surface.
A sports water bottle with a black top and a black strap around its middle, filled with orange liquid, against a plain gray background.

Manufacturing Processes We Support

FormaSharp designs are tailored for a wide range of manufacturing methods—from high-precision CNC machining to mass-production injection molding. We understand the unique requirements of each process and integrate those constraints directly into the design phase.

While we specialize in processes like CNC machining, sheet metal forming, injection molding, 3D printing, weldments, and more, we’re not limited to these. Our design expertise is adaptable, and we’re always open to working with new or specialized fabrication techniques.

If you have a unique process or production method in mind, we’re ready to design for it.

🔹 CNC Machining

  • Precision parts with tight tolerances

  • Optimized for tool paths, fixturing, and material removal

🔹 Milling / Lathe / Drilling

  • Rotational and subtractive processes

  • Designs suited for multi-axis operations and surface finishes

🔹 Injection Molding

  • High-volume plastic components

  • Draft angles, parting lines, and mold flow considerations

🔹 Sheet Metal & Forming

  • Enclosures, brackets, and structural parts

  • Bend allowances, reliefs, and flat pattern optimization

🔹 Weldments

  • Structural frames and assemblies

  • Joint design, weld accessibility, and distortion control

🔹 3D Printing

  • Rapid prototyping and low-volume production

  • Support structure planning, orientation, and material selection

🔹 Metal Fabrication

  • High-strength components with repeatable geometry

  • Grain flow alignment, die design, and material deformation

🔹 Wood Fabrication

  • Furniture, fixtures, and consumer products

  • Joinery, grain direction, and CNC routing for wood

🔹 Glass Molding

  • Decorative and functional glass components

  • Mold design, thermal stress, and surface finish control

A close-up image of six cylindrical metal tubes of varying heights against a black background.

Design Principles We Follow

  • Modern concrete building with glass windows seen from the ground looking up, against a cloudy sky.

    Simplicity: We reduce unnecessary complexity to streamline production and minimize tooling costs.

  • Light painting on a rooftop during sunset with streaks of white light creating abstract patterns against a sky transitioning from orange to deep blue with stars.

    Efficiency: Our designs optimize material usage, reduce waste, and shorten manufacturing cycles.

  • A 3D illustration of a metallic cube structure with smaller cubes connected by rods in a grid pattern.

    Scalability: Whether you're producing one unit or one million, our designs are built to scale.

  • Close-up of frayed and tangled rough-textured ropes in black and white.

    Reliability: We prioritize durability and performance, ensuring your product works as intended in real-world conditions.

Working in Industry

We Speak the Language of Production

FormaSharp works closely with fabricators, machinists, and prototyping partners to ensure your design is ready for the shop floor. We provide:

  • Native CAD files (SolidWorks) and neutral formats (STEP, IGES)

  • Detailed 2D drawings with tolerances and notes

  • BOMs and fabrication instructions

  • Support for remote and local manufacturing teams

We’re your bridge to production.

Close-up of a vented brake rotor.

Designs That Meet Industry Requirements

Our mechanical and industrial designs follow recognized standards to ensure quality, safety, and compatibility:

  • GD&T (Geometric Dimensioning & Tolerancing) for precision and fit

  • ISO, ASME, and ANSI standards for drawings and documentation

  • Industry-specific compliance for medical, automotive, and consumer products

We ensure your product meets the expectations of regulators, manufacturers, and end users.