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Design for Manufacturing (DfM)

The façade industry faces growing demands to deliver projects that are sustainable, efficient, and cost-effective. At Staticus, we address this with our Design for Manufacturing (DfM) system, which simplifies façade elements for easier production and assembly while still allowing for customised architectural design.

This system enables greater standardisation of façade components, significantly reducing waste, embodied carbon, and energy use during manufacturing. At the same time, it improves efficiency, lowers costs, and ensures faster delivery of complex, large-scale projects. 

Designing façades for production efficiency

DfM is Staticus’ own aluminium unitised façade system, developed to align design with the most efficient manufacturing capacities. It was created through a close iterative process between our engineering, technology, and production teams, with a clear focus on waste reduction, efficiency, and sustainability.

By simplifying and optimising the internal panel structure, we enable streamlined manufacturing while retaining full flexibility for bespoke exterior designs. The result is a system that benefits clients through cost-effectiveness, faster delivery, and lower environmental impact.

Key benefits of our DfM façade system

  • Optimised manufacturing

    Standardised aluminium profiles with 90° screw-joined connections simplify production, eliminating corner inserts and cutting fabrication time by up to 20%.
  • Lower environmental footprint

    Reduced material usage help cut embodied carbon.
  • Flexible design freedom

    Bespoke finishes and complex façade geometries remain possible while production stays efficient.
  • Faster delivery of complex projects

    Seamless integration between design, production, and assembly ensures shorter lead times.
  • Future-ready sustainability

    DfM aligns with design for disassembly principles, enabling easier material recovery at end-of-life.

Michigan Avenue Tower 2

The Michigan Avenue Tower 2 project in Manchester marks Staticus’ first UK use of our Design for Manufacturing (DfM) system, and the first structurally glazed façade with fins created using this approach. Spanning 14,109 m², the façade integrates zero transom bulkhead details, purge ventilation windows, and advanced fire-safety solutions.

By applying DfM, we will deliver the project more efficiently and sustainably, with production and installation starting in Q1 2025. Read more.