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How do design defects differ from manufacturing defects?

On Behalf of | Feb 11, 2025 | Products Liability

When a product causes harm, the reason behind the defect determines who is responsible. Design and manufacturing defects are two main types of product flaws that lead to liability claims. Understanding the difference can help you identify the risks and responsibilities tied to a defective product.

What is a design defect?

A design defect occurs when a product is unsafe due to the way it was planned and created. These flaws exist before the product is even made, affecting every unit produced. If a product’s design poses an unreasonable danger to consumers, the manufacturer may be responsible.

For example, if a car model is prone to rolling over during turns due to a high center of gravity, this would be a design defect. The issue exists in every car of that model, making it inherently unsafe even when used as intended.

What is a manufacturing defect?

A manufacturing defect happens when a product is made incorrectly, even though the design is safe. These defects usually occur during production and may only affect certain units rather than the entire line.

For instance, if a batch of bicycle helmets leaves the factory without the proper protective padding, those specific helmets are defective. The design itself is safe, but mistakes in production have made some of the products dangerous.

Why does the distinction matter?

The type of defect influences who may be held responsible in a product liability case. Design defects often result in large recalls or class-action lawsuits since every unit shares the same flaw. Manufacturing defects, however, may only impact a limited number of products, affecting individual claims.

Knowing whether a product has a design or manufacturing defect helps determine liability and strengthens a claim for damages. Understanding these differences can make a big difference in product safety awareness and legal accountability.

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