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How Hardware Startups Use Design for Assembly to Cut Costs

Episode 46 of Hardware Startups with Fexingo dives into Design for Assembly (DFA) — the discipline of designing a product so it can be assembled in fewer steps, with cheaper labor, and less rework. Lucas and Luna break down a real-world case: how a smart-lock startup cut its per-unit assembly cost by 38% just by eliminating six screws and swapping two parts. They walk through the DFA principles that any hardware founder can apply before their first production run, from snap-fit geometry to reducing part count. If you've ever wondered why some hardware startups scale profitably while…

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