Introduction
At Unifabs, we don’t just manufacture sheet metal products – we bring ideas to life through intelligent collaboration, practical design support, and precision engineering. Our design partnership process transforms early concepts and designs into high-quality, manufacturable solutions that deliver in terms of cost, performance, and timescales.
This isn’t a bolt-on service. Design for Manufacture (DfM) is at the heart of how we work – and often, it’s what helps clients overcome challenges, unlock efficiencies, and accelerate delivery.
What is Design for Manufacture (DfM)?
Design for Manufacture (DfM) is the process of optimising a product’s design so that it can be fabricated efficiently, reliably, and cost-effectively using real-world production methods. It’s about making sure what’s designed can actually be made – without unnecessary cost, complexity, or delays. DfM bridges the gap between design intent and production reality, ensuring that form, function, and fabrication are aligned from the outset.
In sheet metal manufacturing, applying DfM best practices from day one can make the difference between a product that succeeds in volume production – and one that doesn’t make it past prototyping.
A proven, stage-by-stage approach
At Unifabs, our sheet metal design for manufacture process follows a clear and collaborative path:
Initial Consultation – We begin with a thorough design review, listening closely to your technical and commercial requirements.
Design Development – Using CAD and SolidWorks, we refine or generate models that are optimised for fabrication and aligned with your objectives.
Prototyping & Validation – Prototypes are produced in-house, enabling fast iteration and functional feedback.
Production Optimisation – Once validated, designs are transitioned to volume production, fully integrated into our metalworking, finishing, and assembly workflows.
This structured approach ensures transparency, de-risks project delivery, and gives you confidence in both the process and the outcome.
Design collaboration from day one
Many projects begin with little more than a sketch or a high-level concept. Our design team gets involved early to shape these ideas into designs that work for sheet metal fabrication. That means selecting appropriate materials, reducing unnecessary complexity, ensuring compatibility with finishing and assembly, and identifying opportunities to minimise cost without compromising function or quality.
Engaging us early means fewer redesigns, faster time-to-market, and greater control over quality and outcome.
Seamless, in-house delivery
Our end-to-end manufacturing capability ensures that the same team supporting your design is also managing its fabrication, finishing, and assembly. From CNC punching and laser cutting to robotic welding and powder coating, everything happens under one roof at our 60,000+ sq ft facility in Warwickshire.
This means tighter control, faster response times, and total alignment between design and delivery.
Case study: CauliBox Kiosk – Complex enclosure, smart solution
One standout example is our work with CauliBox on a bespoke smart kiosk. The challenge? Cost-effectively integrating multiple materials and achieving high visual standards in a compact, modular enclosure for packaging collection.
Unifabs partnered closely with the Cauli team to refine their design for efficient fabrication and assembly. By streamlining components and adjusting fixings and folds, we helped them move to a production-ready unit that met both aesthetic and technical demands – on time and on budget.
Case study: McConnel – Sheet metal design for manufacture (DFM) in agricultural machinery
Our collaboration with McConnel, a leader in agricultural machinery, shows how our DfM best practices apply well beyond the technology sector. Working together on large, formed components requiring strength and precision, we helped optimise their designs for repeatable manufacture – solving supply and performance issues they were experiencing with an original composite part.
This project highlights how early design input from a manufacturer can significantly improve production outcomes in sheet metal fabrication.
Why it matters
For engineers, Unifabs is a thinking partner – not just a supplier. For procurement teams, we help reduce supply chain friction and cost uncertainty. And for operations leaders, our “design through to delivery” model means fewer handovers, tighter control, and a partner who owns the process end-to-end.
Whether you’re developing a new enclosure product, refining an existing design, or seeking a more responsive manufacturing partner, Unifabs is ready to help – from concept sketch to production reality.
Speak to our design team about your next project. Whether you need early-stage input or full production support, we’re ready to collaborate.
Design to delivery, adding value at every stage
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