By Dave Rizzardo, Associate Director, Maryland World Class Consortia

On March 11, 2026, the MWCC Lean Learnings session explored Design for Manufacturing and Assembly (DFMA) with presenter Chad Schneider, P.E., founder of Root3 Labs and a senior mechanical design engineer. Chad shared an insightful overview of Root3’s product development approach and highlighted several best practices that organizations designing new products—or improving existing ones—can apply.

As Chad explained during the session, a more complete description of the approach would be Design for X (DFX). In addition to manufacturing and assembly, Root3 designs for usability, reliability, functionality, installation, and other key factors. This broader optimization requires balancing multiple trade-offs throughout development to achieve the best outcome for the customer.

A central element of Root3’s methodology is an iterative development process that incorporates frequent learning cycles and ongoing input from stakeholders. According to Chad, their ability to develop products quickly is not because they simply work faster—it is because the process itself is designed for speed and learning.  (DR comment – A classic example of working smarter, not harder, and it aligns directly with the Lean principle of “Focus on the Process.”)

These development cycles may begin with very simple prototypes—even cardboard models—to start the learning process early. Chad emphasized the importance of staying focused on what the customer actually needs, rather than automatically incorporating everything a customer initially says they want. By helping customers clearly define the true design objectives, Root3 avoids wasted time and ultimately produces a more optimized final product.  (DR comment – This takes discipline that many engineers do not always practice.)

These early iterations also help minimize lifecycle costs. Once hard tooling is created, the cost of revisions increases dramatically. By refining the design earlier in the development process, Root3 shortens timelines, reduces risk, and helps control overall costs.

Chad also described the range of tools and fabrication methods used throughout the iterative process, including machining, sewing, welding, forming, bonding, and 3D printing. The team intentionally begins with off-the-shelf components whenever possible, only moving to custom solutions when standard options cannot meet the design objectives. This approach improves speed, cost efficiency, and component availability.

Another key principle in Root3’s development philosophy is designing for simplicity. Reducing the number of parts and minimizing complexity creates clear Lean advantages—fewer components to fabricate, store, move, assemble, and manage throughout the product lifecycle.  (DR comment – When viewed through a Lean lens, DFMA—or more broadly DFX—should be considered a critical technique within the product development process.)

While the session focused on Root3’s development methodology, the principles Chad Schneider shared strongly align with Lean thinking. Root3’s approach demonstrates how disciplined product development processes can improve outcomes for customers while reducing cost, risk, and complexity.

Root3 Labs is a Bronze Sponsor of the Maryland World Class Consortia.