How BIM Supports DFMA Workflows in Construction

Building Information Modeling (BIM) plays a central role in enabling Design for Manufacture and Assembly (DFMA) workflows in construction. DFMA emphasizes designing components for easy manufacturing off-site and rapid, accurate assembly on-site. The result is better quality, shorter timelines, and lower costs—especially in large infrastructure and industrial projects.

Unlike traditional design processes that focus on one-off in-situ construction, DFMA shifts the mindset toward repeatable, factory-based production of components. BIM enables this shift by serving as the digital backbone for parametric modeling, clash detection, scheduling, and coordination between design and fabrication teams.

Bentley Tools That Enable DFMA

Bentley Systems provides an integrated ecosystem of tools that support DFMA across the entire project lifecycle. Here's how they work together in a typical workflow:

1. Design and Parametric Modeling

OpenBuildings Designer allows teams to define modular layouts and parametric systems, such as prefabricated rooms or curtain wall assemblies. These models are structured to be easily broken down into repeatable, standardized components suitable for off-site fabrication.

2. Fabrication Detailing

Once the design is finalized, ProStructures (which includes both ProSteel and ProConcrete) is used to add detailed fabrication elements like rebar cages, bolt groups, lifting inserts, and custom connections. This stage bridges the gap between architectural intent and manufacturable geometry, with the ability to export CNC-ready data in formats like DSTV and BTL.

3. Coordination and Review

With the model enriched for fabrication, it can be federated using iTwin Design Review. This cloud-based platform allows stakeholders across disciplines to review and comment on the model, resolving potential clashes and ensuring that all prefabricated systems fit correctly on-site.

4. Construction Planning

SYNCHRO 4D brings time into the equation, allowing teams to simulate how prefabricated elements are delivered, lifted, and assembled. Construction teams can test logistics scenarios, coordinate crane operations, and optimize just-in-time delivery sequences based on actual fabrication outputs.

5. Handover and Asset Management

Finally, once the components are manufactured and assembled, the data-rich model can be passed to AssetWise or iTwin Experience. These tools track component history, monitor performance over time, and support maintenance workflows—all grounded in the original DFMA model.

A Realistic Example: Precast Viaduct Girders

Consider a transportation agency building a precast concrete viaduct. The geometry is modeled in OpenBuildings Designer, then detailed in ProConcrete with lifting anchors and tendon ducts. Fabrication data is extracted for rebar shops and mold fabrication. SYNCHRO simulates installation sequencing with mobile cranes, while the completed viaduct is handed over via iTwin for long-term inspection and maintenance.

🧠 Final Thoughts

BIM provides the structure and intelligence needed for DFMA to succeed in construction. When paired with Bentley's integrated toolchain, project teams can transition smoothly from concept to fabrication to assembly—reducing rework, speeding up construction, and laying the groundwork for future digital twin integration.

To explore Bentley’s DFMA-ready solutions, visit our software page.