Design for Cost: Building Smarter Products from the Start

In manufacturing, most cost-saving efforts come after the design is finished.
But by that stage, you’re locked in. The tooling is built. The processes are agreed. The suppliers are quoting based on decisions already made.

So here’s the hard truth:

Most product costs are set long before a single part is made.

If you want to truly control costs, you need to start earlier, right at the drawing board.

This is where Design for Cost (DfC) comes in.

What Is Design for Cost?

Design for Cost means developing products with cost awareness baked in, not as an afterthought.

It’s not about cutting corners. It’s about making informed decisions:

• Choosing the right materials for function and affordability
  
  
• Simplifying geometry to reduce machining time
  
  
• Standardising parts to reduce inventory
  
  
• Considering assembly early to avoid hidden labour costs
  
  

This approach doesn’t compromise on quality. It reduces waste, avoids overengineering, and delivers better value from the start.

Why Most Teams Miss This

In many companies, design happens in one silo, and costing in another.

Engineering focuses on performance and compliance.
Procurement deals with cost once the design is “done.”
Manufacturing inherits the result and tries to make it work.

By then, the chances to reduce cost without rework are slim.

Fix: Bring cost conversations into design reviews. Use basic cost models and part comparisons to guide early decisions.

3 Practical Ways to Start Designing for Cost

1. Use Cost Comparisons During Concept Selection

Don’t just pick the strongest or sleekest design. Compare the manufacturing cost of multiple options.

Even a quick comparison of material usage, processing time, or tooling needs can highlight big differences — early enough to do something about it.

2. Simplify Features Where Possible

Ask:

• Do we need this undercut?
  
  
• Is this tight tolerance essential?
  
  
• Could this be welded instead of machined?
  
  

Reducing features doesn’t mean reducing function. It means making smarter design calls with cost in mind.

3. Engage Suppliers Early

If a part is complex, don’t wait for the RFQ. Talk to a trusted supplier about manufacturability during the design phase.

They’ll often suggest simpler, cheaper alternatives, and they’ll appreciate being involved.

The Payoff

When you design with cost in mind, you don’t just lower the price, you:

• Reduce time-to-market by avoiding late rework
  
  
• Improve supplier engagement with clearer, more buildable parts
  
  
• Protect your margins from day one
  
  

You also empower your teams to make better decisions because they understand the cost consequences of their work.

Design Is Where Cost Lives

If you want better control of product cost, start where the cost begins, with design.

It doesn’t take complex tools. It takes the mindset to ask better questions early, and the systems to support smarter choices.

Because the best time to save cost… is before it ever gets built.