Design for manufacture and assembly (DfMA) for modular buildings: an analytical framework

Design for Manufacture and Assembly (DfMA) is a proactive strategy aimed at maximizing the potential of modular buildings to address issues, including labor shortages, time overruns, and low productivity. Despite its growing adoption, research on examining existing design practices remains limited. This study therefore aims to 1) develop an analytical framework and 2) uncover underlying modular building design patterns. Drawing inspiration from space syntax analysis, the framework comprises six components: nomenclature system, space identification, spatial relations, module shape, dimensions, and convex break-up. It was then applied to analyze 39 modular building units in Hong Kong. The established framework helps visualize underlying design patterns, e.g. spatial typologies, module shapes and sizes, and standardized spatial configurations. Several design patterns are also identified, i.e. typical space requirements, common module sizes, dimension-coordinated spaces, and the repetitive use of standardized spaces and modules to form units. This innovative framework, along with a discussion on evolving professional practices, offers valuable insights for advancing DfMA and modular construction. Future research is recommended to refine the framework and enhance DfMA by integrating these patterns with expert knowledge and computational intelligence.