Wear- yet impact-resistant demand is a big challenge for coated components under heavy-load service condition. To solve this high-performance manufacturing problem, a new strategy of design for manufacturing (DFM) with integrated design and processing is developed by incorporating processing effect on final performance via the pivot role of surface integrity. An impact performance tester and the model on thermodynamics are constructed for a component with coated flat block/bulk cylinder mates to potential application in hydraulic machinery. A WC-12Ni/Ni60A two-layer coating on 17-4PH substrate is designed with thermal spray process. Impact crater depth, surface hardening and residual stresses are identified as major surface integrity parameters. The design parameters of geometry, material and structure are quantitatively linked to the performance by a process signature (PS) correlation between identified surface integrity and internal material loading of plastic/elastic strain energies. The PS correlation posts coating thickness as a high-sensitivity parameter, facilitating a buffering effect of reduced peak stresses among the coating-substrate system. The DFM optimization is understood by irreversible thermodynamics as reducing energy dissipation of the internal material loading from the external impact loads. The manufacturing inverse problem is thus solved by material-oriented regularization (MOR) on the homologous PS correlations integrating the design and processing phases. The manufactured component, with optimal Ni60A interlayer thickness of 75-100 µm at a top WC-12Ni coating of 200 µm, achieves a desired performance up to 6000 impacts under a nominal load of 15 kN.