Insights from Formaspace leadership on how a structured, manufacturer-led process reduces risk from design through installation
Custom lab and industrial furniture rarely starts as a creative exercise. More often, it begins as a practical response to real constraints. Spaces cannot move. Equipment does not fit standard dimensions. Workflows require functionality that existing systems were never designed to support.
“Most projects don’t begin with the intention of going fully custom,” says Brett Gray, Industrial Design Manager at Formaspace. “Teams typically explore standard and modified options first. It’s only when those options stop supporting the work that custom becomes part of the conversation.”
That shift can happen for many reasons. Fixed utilities may limit layout options. Equipment footprints or loads may exceed what standard systems are designed to handle. In other cases, the challenge is not spatial at all. New processes, specialized instrumentation, or missing functionality can require solutions that simply do not exist within pre-engineered offerings.
When custom is approached well, it can unlock performance, efficiency, and long-term flexibility that standard or lightly modified solutions cannot deliver. That potential, however, only materializes when the process behind the work is clear.
“This is the point where projects either gain alignment or start to accumulate risk,” explains Corey Hutchins, COO at Formaspace. “Without clear ownership of the process, decisions get delayed, assumptions creep in, and teams lose momentum.”
Where Custom Furniture Projects Commonly Break Down
Most challenges in custom projects do not come from a lack of expertise. They come from a lack of clarity.
One of the most common breakdowns occurs when requirements are loosely defined. Goals may be discussed, but critical details such as equipment access, utility routing, tolerances, or future reconfiguration are left open to interpretation.
“Everyone feels aligned early on,” says Brett Gray. “But unless those assumptions are surfaced and resolved, they tend to show up later as redesigns or change orders.”
Feasibility is another frequent inflection point. Early concepts may look correct visually, but without engineering involvement at the right stage, material behavior, structural loads, or fabrication constraints can be underestimated.
“We see this especially when equipment integration is involved,” notes Travis Spoor, Director of Engineering at Formaspace. “A concept might make sense spatially, but once we evaluate loads, vibration, or service access, the design needs to evolve.”
Late-stage changes compound these issues. When design decisions are not formally reviewed and signed off before moving into engineering or production, even small revisions can ripple through schedules, cost, and quality.
“Once fabrication starts, the cost of change increases dramatically,” Travis adds. “That’s why timing and decision discipline matter so much.”
Why Structure Changes the Outcome
Structure does not limit custom work. It enables it.
Clear definition early in the process creates a shared understanding that carries through design, engineering, and manufacturing. Decisions are made deliberately rather than reactively, which reduces rework and protects timelines.
“Structure is what allows teams to move faster later,” says Corey Hutchins. “When expectations and constraints are clear, everyone can focus on execution instead of revisiting decisions.”
Defined decision points and formal sign-off moments play a critical role in maintaining momentum. By confirming alignment before a project transitions from definition to design, and again from design to production, teams lock in decisions with confidence and reduce downstream risk.
This approach also builds trust with clients. Knowing when decisions are finalized, and understanding why, removes uncertainty and helps projects move forward predictably.
What a Disciplined Custom Process Looks Like
Successful custom projects follow a disciplined but flexible path because complexity demands coordination. Each phase builds on the last, creating momentum instead of rework as projects move from concept to completion.
The process begins by defining the problem before designing a solution. This means understanding not only how the space is laid out, but how it needs to function. Teams look closely at how equipment is used, how people interact with it, which constraints are fixed, and where adaptability is essential.
“Good design starts with asking the right questions,” says Brett Gray. “If you rush past definition, you end up solving the wrong problem very efficiently.”
From there, design and engineering move forward together. Concepts are developed with manufacturing in mind, allowing materials, tolerances, performance criteria, and fabrication methods to be evaluated as ideas take shape.
“That collaboration is where risk is removed,” explains Travis Spoor. “Through Formaspace’s Co-Create: Fit & Finish, process, design and engineering work side by side early on, so by the time a design reaches production, we already know how it’s going to be built and how it will perform.”
Delivery is where intent becomes reality. Manufacturing, quality control, and installation support are treated as extensions of the design and engineering process, not final handoffs.
“Our responsibility doesn’t end when drawings are approved,” says Corey Hutchins. “It carries through fabrication, inspection, and installation readiness.”
Knowing When to Modify—and When to Go Fully Custom
Not every project that starts as “custom” actually requires a full custom workflow.
In many cases, adjusting dimensions, reconfiguring storage, or integrating accessories can be handled as modifications. These changes leverage existing designs and manufacturing processes to reduce lead time and complexity.
True custom is reserved for projects that require original design development, new structures, or unique integration challenges. Knowing the difference is part of the manufacturer’s responsibility.
“Custom isn’t about doing something different for the sake of it,” Corey notes. “It’s about applying the right level of effort to solve the problem effectively.”
Co-Creating the Fit: A Simple Checklist
If the ideas above have you wondering how custom work actually comes together, this is how we co-create with clients. It’s intentionally light on jargon and focused on maintaining momentum while reducing risk.
- Start with outcomes, not parts.
Begin with a concise brief that defines what the space must accomplish, what constraints are fixed (utilities, equipment, compliance), and how success will be measured. This keeps decisions grounded in purpose rather than product. - Walk the workflow.
Trace how people, samples, carts, and data move through the space. Photos, dimensions, and adjacency notes help anchor the design to how work really happens, not how it looks on paper. - Align materials and performance to the work.
Confirm worksurfaces, load requirements, cleanability, and durability based on actual protocols. Materials should support the work, not dictate it. - Engineer for buildability.
Design and engineering work together to route services, confirm tolerances and clearances, and resolve complex interfaces early. This is where many downstream issues are eliminated. - Lock decisions with coordinated submittals.
Provide a single, coordinated package that includes layouts, elevations, utility notes, and supporting assets. Clear documentation and formal sign-off allow projects to move forward without churn. - Prototype when it reduces risk.
For novel or high-impact elements, validate fit, access, and human factors through targeted mockups before fabrication begins. - Build, stage, and sequence intentionally.
Manufacturing proceeds with agreed finishes and quality checkpoints. Deliveries are phased to align with site readiness, protecting both the product and the schedule. - Install, verify, and tune.
Confirm utilities and paths of travel, complete installation, close punch items, and provide a brief orientation. At 30 and 60 days, we check back in to confirm what’s working and make small adjustments that help the space perform better over time.
Quick rule of thumb:
If your need involves dimensional adjustments or storage reconfiguration, a modified solution is often sufficient. If it involves new loads, integrations, or functional requirements beyond standard platforms, you’re in custom territory—and this checklist becomes your roadmap.
Custom Works—When It’s Done with Discipline
Custom is not the challenge. An unclear process is.
When manufacturers take responsibility for leading the process, setting expectations, aligning teams, and guiding decisions, custom becomes a strategic advantage rather than a risk.
At Formaspace, this approach is formalized through Co-Create: Fit & Finish, a structured and repeatable framework that brings clarity and alignment to complex custom lab and industrial furniture projects while preserving the adaptability and creativity those projects require.
When custom is done the right way, it delivers exactly what it is meant to deliver. Solutions that fit the work, the space, and the future.
