More of Bunnie Huang's amazing series on manufacturing in China for makers (part one): today, it's a piece on understanding and designing to the constraints of the kind of manufacturing a startup can afford:
Trim and finish are difficult, and therefore a point of distinction when it comes to design. The current design fad is minimalism, with an emphasis on "honest" finishes. An honest finish features the natural properties of the material systems in play, and eschews the use of paints and decals. Minimalist, honest designs are very hard to manufacture. Minimal designs have…well, minimal, features – and as a result even tiny blemishes stand out. Honest finishes likewise can be very difficult, as an honest finish means no paint: all the burs, gates, sinks, knits, scoring and flow lines that are a fact of life in manufacturing are laid naked before the consumer. As a result, this school of design requires well-made tools that are constantly checked and maintained throughout production.
If you don't have pockets deep enough to invest in new equipment and capabilities on behalf of your factory (i.e., if you're not a Fortune 500 company), the first step is to learn the vocabulary available. A design vocabulary is defined by the capabilities of the factory or factories producing the goods. What materials, what finish, what tolerances are achievable, what fastening technology is available – these are all heavily dependent upon the processes available.
Therefore, I find that visiting a factory in person early in the design process results in a better design result. In a factory visit, some design vocabulary will be discarded, but some new vocabulary will be discovered as well – the engineers who work the factory day in and day out develop process innovations that can open up novel design possibilities that are not knowable without the on-site visit.