When a product causes an injury, one of the first questions is whether the problem was a design defect or a manufacturing defect. Munley Law’s product liability lawyers work with clients to uncover what went wrong and determine the best path forward under Pennsylvania law.
What is a Design Defect in a Product Liability Case?
A design defect means that the product was unsafe from the start. Even if it had been made exactly as intended, the design itself posed a danger. In Pennsylvania, courts consider whether a safer design of the product would have reduced the risk of injury without compromising its functionality.
The key idea is that the problem isn’t a one-time mistake in production. It’s the product’s design that makes it unreasonably dangerous for users.
For example, imagine a lawnmower built with exposed blades and no safety guard. Even if every lawnmower comes off the assembly line exactly the same, the design still puts users at risk. Munley Law has handled cases involving industrial machines where the layout, configuration, or operation made serious injuries likely and foreseeable.
To decide these cases, Pennsylvania courts weigh the product’s usefulness against the risks it creates. They often rely on experts to explain safer design options, basic engineering principles, and the industry-standard safety standards.
Contact a Personal Injury Lawyer at Munley Law
Call Us At 844-686-5397 What is a Manufacturing Defect?
A manufacturing defect occurs when something goes wrong during the production of a product. The design itself may be perfectly safe, but a mistake during production, assembly, or quality control makes that particular item dangerous. Unlike a design defect, the problem isn’t with every product in the line, but only with those built incorrectly.
For example, a forklift with a misaligned hydraulic system that causes sudden drops may have a manufacturing defect. Munley Law has represented clients injured by defective forklifts, including cases in which a production error led to catastrophic injuries, such as amputation.
These cases focus on whether the product was built as intended.
In Pennsylvania, you don’t have to prove the design was unsafe. The key question is whether the specific product was defective at the time it left the manufacturer’s control and whether that defect caused the injury.
Key Differences Between Design and Manufacturing Defects
Both design defects and manufacturing defects can support a product liability claim in Pennsylvania, but courts look at them differently.
- Design defect: The problem is in the product itself. Every unit is potentially dangerous because of its design. These cases usually focus on whether a safer, practical design could have been used and how the risks compare to the product’s benefits.
- Manufacturing defect: The design may be fine, but something went wrong during production. Only certain units are unsafe because they were built incorrectly. The focus here is on whether the product strayed from its intended specifications or accepted industry standards.
Knowing which type of defect is involved matters. It affects who may be responsible and what evidence is needed. Design defect cases usually depend on engineers or safety experts. Manufacturing defect cases often come down to paperwork such as factory records, inspection reports, and quality control logs that show where something went wrong.
“Since 1959, we have secured over $1 billion in
compensation for our clients.”
Daniel W. Munley
Who Can Be Held Liable for a Defective Product?
Both types of defects may lead to claims against manufacturers, distributors, importers, and, in some cases, retailers. Pennsylvania recognizes strict liability in product cases, meaning plaintiffs do not need to prove negligence if the product was sold in a defective condition.
Munley Law has had cases involving both foreign manufacturers and U.S. distributors, focusing on clear proof that ties the injury directly to the defective product. Identifying the origin of the defect is critical to determining who is liable and what compensation may be available. Federal law also requires manufacturers, importers, and distributors to report products that pose a substantial risk of injury to the Consumer Product Safety Commission, which can play an important role in product safety investigations.
Common Products Involved in Defect Claims
Design defects and manufacturing defects show up across a wide range of industries:
- Industrial equipment: Forklifts, presses, and heavy machinery can be dangerous due to poor design or production mistakes.
- Medical devices: Pacemakers, implants, and surgical tools can fail due to design flaws or manufacturing errors.
- Consumer products: Appliances and power tools may become unsafe if they’re assembled incorrectly or designed in a way that creates unnecessary risk.
- Transportation: Automotive and aviation components, such as airbags or gas gauges, may be defective by design or manufacturing.
Munley Law recovered $32.25 million in a product liability case involving a plane crash caused by a defective gas gauge, illustrating the high stakes in both design and manufacturing defect claims.
Proving a Design or Manufacturing Defect in Pennsylvania
In Pennsylvania, a defect can either be a mistake that happened during production or a design that’s unsafe from the start under § 402A. Courts consider evidence such as production records, safety manuals, and expert reports to determine whether the product posed a real risk to a person using it normally.
Impact on Damages and Financial Recovery
Both design and manufacturing defects can result in severe, long-term injuries with lasting consequences. These claims may include compensation for medical expenses, rehabilitation costs, lost income, and ongoing care.
Our attorneys work to thoroughly document how the injury affects your daily life, ability to work, and future financial stability to ensure the full scope of your losses is recognized.
Frequently Asked Questions About Design Defects and Manufacturing Defects
Can a Product Have Both a Design and a Manufacturing Defect?
Yes. A product may be defectively designed and have production errors. Pennsylvania courts consider each defect independently.
Does Strict Liability Apply To Defective Products?
Yes. In Pennsylvania, you don’t have to prove the manufacturer was negligent. You just need to show that the defect caused the injury.
Are Retailers Ever Responsible for a Defective Product?
Retailers can be held responsible if they sell a product without proper warnings. But usually, the manufacturer is the main party the claim targets.
What Types Of Experts Are Used in Product Defect Cases?
In cases of design defects, engineers or safety specialists may demonstrate how the product could have been safer. In cases of manufacturing defects, experts often focus on production or quality-control issues.
Speak With a Pennsylvania Product Liability Lawyer Today
Munley Law offers free consultations for anyone harmed by a design or manufacturing defect, and we charge no fees unless compensation is recovered.
Our attorneys carefully review the product, accident reports, and safety records to assess the strength of your claim and have a record of multi-million-dollar recoveries in complex cases. We have also received awards and recognition for our work, with Marion Munley and Daniel Munley both named Lawyer of the Year for Product Liability Litigation by Best Lawyers.
Contact us today to discuss your defective product claim.
Daniel W. Munley
Daniel W. Munley is an award-winning personal-injury attorney and champion of plaintiffs’ rights. For decades he’s won multi-million verdicts and settlements and is recognized as a national leader in truck and rideshare litigation,including a record $26 million truck settlement in Northeastern Pennsylvania and a $20 million recovery in 2024 for life-altering commercial-vehicle injuries.
