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The phrase "a design fault" is correct and usable in written English.
You can use it when referring to a flaw or error in the design of a product or system that affects its functionality or performance.
Example: "The product was recalled due to a design fault that could lead to safety issues for users."
Alternatives: "a design flaw" or "a design defect".
Exact(24)
"There is a design fault in us," Martagon concludes.
A design fault is harder to fix if the foundry is thousands of miles away.
H2 had a design fault, and Harrison never allowed it to be tested at sea.
Then there is a worry that the EFSF may have a design fault.
The carmaker needs to spot the trend, recognise it as a problem and then determine whether or not it is a design fault that requires wholesale replacement.
This is due to the unforecasted spike in activity levels and the complicated logistics rather than a design fault with record-keeping".
Similar(36)
A designed fault tolerant control scheme does not require system identification process and it provides an effective reconfigurability without fault detection and isolation (FDI) process.
Both of them say it was their fault, not a design flaw.
Cracks in a ceramic package may also indicate a package design fault or excessive mechanical stresses.
The image of a submarine with a big hole in its side, captioned "Just as we set out on our first voyage I spotted a major design fault," would not get by a good editor.
It is happening so often – just outside the three-year warranty – that there is a clear design fault.
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Since I tried Ludwig back in 2017, I have been constantly using it in both editing and translation. Ever since, I suggest it to my translators at ProSciEditing.

Justyna Jupowicz-Kozak
CEO of Professional Science Editing for Scientists @ prosciediting.com