Design for sustainability

Food spoilage is a pervasive issue with significant implications for public health, economic stability, and environmental sustainability. Addressing food spoilage is essential to promoting healthier living, reducing economic waste, and ensuring sustainable practices. When storing food in refrigerators, it would be crucial to monitor at least factors such as temperature, humidity, and signs of spoilage to ensure food quality and safety. The paper presents a concept for a smart fridge equipped with sensors to monitor critical factors such as temperature, humidity, and spoilage indicators. These sensors collect real-time data, which can be visualized through a multisensory eXtended Reality (XR) Digital Twin that provides a highly realistic 3D visualization of the real fridge, incorporating dynamic temperature simulations represented through 3D color maps and an olfactory simulation that replicates the smell of rotten food. The first impressions of the Multisensory XR Digital Twin emphasize its effectiveness in bridging the gap between raw data and user perception, allowing for an immersive interaction with the fridge as if physically present. Key benefits identified include enhanced spatial awareness and realism, multisensory feedback, and greater user engagement.

Keywords: Circular Economy , Digital Twins , eXtended Reality , Multisensory experience

Wire Arc Additive Manufacturing (WAAM) is a promising approach for the sustainable production of large-scale metal components. This study presents the first prospective Life Cycle Assessment (LCA) focused on the gate-to-gate manufacturing stage of seven patented, currently immature WAAM technologies. These technologies are projected to reach industrial maturity by 2035 and are evaluated in both laboratory-scale and anticipated industrial-scale configurations. Key findings reveal that future WAAM systems may reduce environmental impacts by an average of 45 % at the lab-scale and 74 % at the industrial scale compared to current WAAM. Argon shielding gas consistently contributes to more than 70 % of the total environmental impact. Plasma-based future WAAM significantly outperforms electric arc variants, exhibiting at least 20 % lower environmental impact than current WAAM systems. Multi-axis WAAM also demonstrates environmental advantages, with a 21 % lower impact compared to planar setups at the lab scale.

Keywords: Prospective LCA , Sustainable manufacturing , Technological forecasting , Wire Arc Additive Manufacturing

The purpose of this paper is to evaluate the evolution of sustainability research in Additive Manufacturing (AM) by providing an overview of systematic literature reviews (SLRs) published between 2016 and early 2025. Nine SLRs were selected following the screening and filtering of 204 records identified through a structured search of the Scopus database. The following criteria were used to analyze and compare these articles: (i) their scope, (ii) data sources of literature considered, (iii) sustainability dimensions covered, and (iv) the main findings and key conclusions (e.g., significant patterns, recurrent themes, methodological advancements). The study highlights that AM is widely recognized as a transformative technology capable of fostering more sustainable, localized, and resilient production systems. However, realizing its full sustainability potential requires further research, methodological standardization, integration of lifecycle thinking, digitalization, and greater attention to social dimensions. Although AM demonstrates clear economic advantages, the social pillar of sustainability remains underexplored, with limited research addressing concerns such as occupational health risks and the demand for skilled labor in emerging economies.

Keywords: Additive manufacturing , Meta-review , Sustainability

This paper explores proactive manufacturing repurposing as a strategic design and business opportunity beyond traditional sustainability and crisis-driven motivations. Through the analysis of nine case studies across diverse sectors, we identify key external and internal factors that influence firms' ability to repurpose components and products across applications. At the external level, market demand, technology cycles, and infrastructure compatibility shape the feasibility of second-life applications. At the internal level (design-related factors), product design features—especially modularity and life-cycle alignment—emerge as critical enablers or constraints. The findings highlight the need for cross-application opportunity assessment tools and design methodologies that balance upstream performance requirements with downstream repurposing potential. This study opens new avenues for circular design, strategic innovation, and repurposing-aware product development.

Keywords: Cross-application innovation , Design for circularity , Manufacturing strategy , Modular product design , Proactive repurposing

Despite the increasing environmental awareness, sustainable products are not routinely adopted, revealing a persistent attitude–behavior gap. While this gap has been widely studied through psychological and behavioral approaches, less attention has been given to how product design attributes shape users' perceptions and influence their interaction with products. Therefore, this article aims to explore the literature on the role of design attributes in this context, analyzing how product design attributes and sustainability cues affect user experience and product-related decisions. Based on a systematic literature review process, 52 articles were extracted from the SCOPUS database. These articles were classified and analyzed according to their main objectives. Based on the findings, attribute centrality (i.e., whether a product feature is perceived as central or peripheral to the product's identity) and product category (utilitarian or hedonic) are relevant to shape environmental attitudes and behavior. Specifically, sustainability cues tend to be perceived more negatively in utilitarian products, where functionality is prioritized, and more positively in hedonic products, where they may enhance emotional value, especially when perceived as central attributes. Therefore, these characteristics must be strategically integrated in product design to reduce the perceived trade-off between sustainability and performance. The review conclusions highlight the need for further investigation to identify how specific product design attributes resulting from the application of ecodesign principles trigger sustainability perception.

Keywords: Attitude–behavior gap , Design attributes , Product category effects , Sustainability perception , User perception

Environmental sustainability and increasingly stringent emission regulations are accelerating the electrification of non-road mobile machinery. While retrofitting presents a cost-effective path forward – particularly for small and medium-sized manufacturers – it often fails to unlock the full benefits offered by electrification. This shortfall is especially evident in machines that retain traditional hydraulic architectures, where energy inefficiencies persist. This study focuses on the virtual prototype of a retrofitted battery-powered material handler derived from an internal combustion engine variant, where the original load-sensing hydraulic system remains unchanged. Being previously validated, the virtual prototype is used to investigate a novel energy-saving control strategy. This strategy controls the electric motor speed based on the combined efficiency map of the electric motor and hydraulic pump, moving beyond conventional load-sensing control logic. The paper focuses on the modeling methodology for both components. Then, simulations show that control optimization based on combined efficiency reduces the energy consumptions compared to the baseline strategy. Indeed, overall efficiency of the machine increases from 36.6% to 39.1%. The proposed approach offers a cost-efficient pathway for improving performance without requiring extensive mechanical modifications, thus supporting broader electrification in the non-road mobile machinery industry.

Keywords: Electrification , Multi-physics Modeling , Non-Road Mobile Machinery , Off-Highway Vehicles

3D printing is transforming the construction industry by reducing material waste, enhancing design flexibility, and shortening construction timelines. As a rapidly advancing technology, it offers innovative solutions for efficient, sustainable, and advanced building practices. This study aims to give an overview of the contents treated in the literature on 3D printing of concrete, with a focus on key topics, technologies, applications, and parameters influencing printability. Following a systematic review process, 1079 studies were analyzed in terms of objectives, structural applications, and printing technologies. The findings reveal a strong emphasis on parameters such as strength, interlayer bonding, and rheological properties, while durability-related aspects like freeze-thaw resistance and water absorption are explored more seldom. The study underscores the need for material optimization to balance fresh-state and hardened-state properties, ensure long-term structural performance, and incorporate sustainable materials. By addressing these gaps, this research identifies critical pathways for advancing 3D printing in construction and provides recommendations for achieving durable, efficient, and environmentally sustainable solutions.

Keywords: 3D Printing , additive manufacturing , construction sector , structural applications

The recent increase in environmental challenges and concerns has enhanced global awareness, forcing a shift towards sustainable manufacturing to improve resource efficiency and reduce waste generation. Additive Manufacturing (AM) is considered sustainable, albeit in different ways depending on context and products. This study aims to shed light on AM adoption, highlighting how experts perceive the sustainability of AM, and this affects the selection of AM for part fabrication. A semi-structured interview revealed that experts have diverse perspectives on using AM, recommending or rejecting it for producing specific parts and identifying distinct sustainability hotspots. The hotspots classified under process sustainability were the most critical factors in process selection, followed by those about corporate and part (i.e., structure and geometry) sustainability. Overall, reducing the mass of raw material, reducing production time, part customizability, and surface quality resulted as the most mentioned factors within manufacturing process selection. Overall, AM was found to be more suitable than traditional manufacturing for process sustainability primarily due to time and cost, corporate sustainability for product customizability, and less for part sustainability due to poor finishing.

Keywords: Additive manufacturing , Decision-making , Environmental hotspots , Expert , Semi-structured interview , Sustainability

3D printing offers transformative potential in construction, yet optimising the performance of cementitious materials before and after extrusion remains a critical challenge. This study presents a performance-based mix design framework targeting extrudability, buildability, and layer stability, while evaluating the individual and combined effects of cement (C), hydrated lime (L), recycled tile powder (T), and chemical accelerators (A). Results reveal that their synergy significantly enhances rheology, yield stress, and print stability, while maintaining sufficient flowability. A specifically optimised mix, CLTA, achieved a 40% reduction in shrinkage, improved interlayer bonding, and markedly increased mechanical strength, modulus of toughness, and failure strain, key for energy absorption in printed structures. Environmentally, CLTA reduced raw material demand and improved eco-strength and cost-efficiency by up to 20%, promoting circularity and resource efficiency. The findings provide a robust pathway for designing high-performance, sustainable 3D-printed mortars, integrating engineering functionality with ecological resilience, paving the way for broader adoption of additive manufacturing in construction.

Keywords: 3D printing , cementitious mixtures , mechanical properties , printability , sustainability , viscosity

Global demographic shifts, particularly the growing elderly population and their need for chronic disease management are straining healthcare systems. Innovative models that emphasize telemedicine and digitalization offer promising solutions to improve care and reduce costs. To evaluate the feasibility and sustainability of such a model, an adaptive mixed-methods approach, including dynamic context monitoring and a Strengths, Weaknesses, Opportunities, and Threats (SWOT) analysis, was employed. A preliminary three-month regional study aimed to prevent acute events in older adults and enhance the quality of life using digital devices for self-monitoring vital signs was conducted. These data were transmitted in real-time to a platform monitored by general practitioners. Despite the short experimental period, early findings are promising, indicating the model's potential for scalability and adaptability to various settings, such as protected discharge or chronic care programs. However, addressing challenges like internet connectivity, healthcare professional engagement, sociocultural resistance, and the need for ongoing training is crucial. Effectively managing these factors while leveraging existing strengths and opportunities could lead to more efficient, responsive healthcare systems.

Keywords: Healthcare , Healthy and Active Ageing , Older adults , Sustainability , Telemedicine

The transition to clean and sustainable transportation highlights the importance of hydrogen and fuel cell technologies as promising solutions for reducing greenhouse gas emissions. This paper presents the development and assessment of an adaptive frequency separation-based energy management strategy using fuzzy logic for fuel cell–battery hybrid vehicles. The studied system integrates a proton exchange membrane fuel cell as the primary source and a lithium-ion battery as the secondary source, both interfaced with the DC bus through DC/DC converters. A PI controller ensures DC bus voltage stability, while a sliding mode hysteresis controller provides robust regulation of the fuel cell current. Unlike conventional frequency separation methods, which only allocate low-frequency demand to the fuel cell and high-frequency demand to the battery, the proposed strategy introduces an adaptive correction mechanism based on the state of charge (SOC) of the battery and instantaneous load variations. This ensures efficient power allocation according to source dynamics while actively regulating the SOC within a safe operating range. Simulation results under UDDS and NEDC driving cycles confirm that the proposed strategy maintains the SOC between 40% and 80% with convergence toward the target value of 60%, while reducing the apparent hydrogen consumption by 30%. These improvements highlight the robustness and efficiency of the proposed strategy, making it a promising solution to extend the lifespan of hybrid energy sources in hybrid fuel cell electric vehicles.

Keywords: Energy management strategy , Frequency separation , Fuel cell hybrid electric vehicle , Fuzzy logic , Hydrogen , PI controller , Sliding-mode control

This study investigates the development of advanced technologies for subsurface monitoring, with significant implications in geophysics, natural hazard mitigation, and environmental engineering. Specifically, the research focuses on the application of Distributed Acoustic Sensing using a 28 km long scientific electro-optical cable deployed in deep-sea conditions as a sensor for the detection of vibrations and mechanical disturbances along its path. DAS enables continuous, high-resolution monitoring of the underwater acoustic environment. However, the system's sensitivity and accuracy are strongly influenced by the degree of mechanical coupling between the optical fiber and the surrounding medium, which in turn depends on both the structural characteristics of the cable and the nature of the seabed where it is installed. To address these challenges, a digital twin of the experimental configuration has been developed. This virtual model allows for the simulation and optimization of the cable's mechanical behavior under various environmental conditions. Particular emphasis is placed on the analysis of the cable's static equilibrium state, which is essential for understanding the actual transmission of mechanical stress to the optical fiber and for the calibration of numerical models against experimental data. The manuscript is organized as follows: Introduction, Cable Architecture, Experimental Setup, Methodology, Results, and Conclusions.

Keywords: Digital twin , Distributed Acoustic Sensing (DAS) , Mechanical Coupling , Optical Fibers

The GeoINQUIRE project (GEO_INQUIRE, HORIZON-INFRA-2021-SERV-01, GA - 101058518) is a European initiative aimed at developing innovative research infrastructures for monitoring the subsurface, with applications in the fields of geophysics, natural hazards and environmental engineering. In this context, the Laboratori Nazionali del Sud – Istituto Nazionale di Fisica Nucleare are working on the application of Distributed Acoustic Sensing (DAS) technology, using a proprietary 28 km-long scientific deep-sea electro-optical cable as sensor to detect vibrations and mechanical changes along its path, to provide continuous, high-resolution monitoring of the soundscape. The effectiveness of DAS in such applications depends on the ability to accurately simulate the response of the system, since the mechanical coupling between optical fiber and soil, mediated by the cable jacket, varies significantly depending on the type of cable used and the characteristics of the soil (rocky, sandy, etc.). To address this issue, the development of a digital twin of the configuration has been initiated to model, simulate and optimize the behaviour of the optical fiber under different operating and environmental conditions and using cables different manufacture. The integration of experimental data into digital simulations enables the prediction and improvement of DAS performance, helping to optimize design solutions and promote the evolution of smart manufacturing.

Keywords: Digital twin of optical fiber cable , Distributed Acoustic Sensing , Mechanical coupling , Modal analysis , Optical fibers cable manufacture

Comfort is a pivotal construct in human-centered design, connecting technical functionality with well-being across products, services, and systems. The 2023 International Comfort Congress (ICC2023) brought together researchers and practitioners to explore how new contexts of use, predictive approaches, and user diversity are reshaping this field. Contributions in this special issue address comfort in automated driving and turboprop aviation, where physical, psychological, and environmental factors converge. Advances in predictive comfort science demonstrate how objective measures, physiological sensing, and modeling complement traditional self-reports. At the same time, inclusive design approaches—ranging from XR-based co-creation to analyses of posture and movement variability—highlight the importance of accounting for heterogeneous user needs and comfort trade-offs. Together, these studies illustrate a shift toward more adaptive, accessible, and sustainable systems, underscoring comfort as a multidimensional construct that evolves with technological innovation and societal change.

Keywords: accessibility , automated driving , comfort research , human-centered design , predictive modeling , user diversity

The EcoDAM (Eco-Design for Additive Manufacturing) project presents a comprehensive framework aimed at enhancing the environmental sustainability of metal additive manufacturing (AM) processes. Recognizing the complex interdependencies between material selection, manufacturing technologies, and lightweight design, the framework integrates four key steps: sustainable technology selection, lightweight design optimization, and a two-phase parametric life cycle assessment (LCA) involving both objective function formulation and constraint definition. Innovative methodologies such as function-oriented patent analysis, topological and lattice structure optimization, and parametric LCA modelling are employed to systematically evaluate and minimize environmental impacts throughout the AM product lifecycle. A case study based on Ti6Al4V connecting rod produced by laser powder bed fusion demonstrates the application of the framework, resulting in more than 50% weight reduction and improved sustainability performance. Key parameters, such as cell size and wall thickness of gyroid lattice structures, are optimized using finite element modelling simulations, while LCA constraints are formulated using experimental and literature-based data. The framework's modular design allows for industrial integration using commercial tools, enabling scalable, data-driven, and environmentally informed decision-making in AM. EcoDAM thus contributes a robust methodology for advancing circular economy goals in industrial AM.

Keywords: Additive manufacturing , Eco-design , Lightweight design , Parametric LCA , Patent analysis , Prospective LCA

Directed Energy Deposition (DED) is increasingly utilized for the construction of large components, repair of worn and damaged parts, and integration into Hybrid Manufacturing systems to leverage diverse technological features. A burgeoning application of DED is in Additive Remanufacturing (ARem), by which existing components can be enhanced with additional features and materials to improve functionalities. This paper presents a systematic and integrated approach for Design for Additive Remanufacturing (DARem), focusing on the optimization of product structural requirements to enhance performance and the process design to minimize flaws while ensuring material integrity and expected tolerances. The suggested approach involves product and process design phases within a computer aided design platform. Identification of critical issues in the original product design is the fundamental phase that drives the selection of the appropriate materials and quantities for deposition. Next, topological optimization is employed to shape and position additional volumes, generating enhanced design variants. A simulation phase ends the product design steps, assessing the actual improvement of the component over its original design. Subsequent phases are related to process design assessment. Selection of process parameters and build strategies, and next, the behavioral simulation of deposition are fundamental to verify feasibility and generate paths instructions. Finally, thermomechanical simulation is conducted to estimate the final component state accurately, ensuring it meets functional requirements before proceeding to actual manufacturing pre-processing, material deposition, and post-processing phases. A case study involving an automotive suspension component is used to demonstrate the feasibility of the proposed integrated approach. Experimental phases are performed to define DED material properties for the redesign and investigate the reliable simulation of process-induced distortions. By reducing stress in critical areas through localized deposition of 316L stainless steel alloy using laser powder DED, the study explores the impact of toolpath strategies on process-induced distortions through a Design of Experiments (DoE) approach. The results confirm the feasibility of the deposition process in meeting functional requirements, particularly geometrical tolerances, highlighting the potential of DARem for the redesign and enhancement of existing components.

Keywords: 316L, Remanufacturing , Directed Energy Deposition , Finite Element Method , Product-Process design

This paper proposes an innovative framework based on artificial intelligence techniques to optimize the reuse of End-of-Life (EoL) ICT components. The system integrates two complementary modules: (1) zero-shot identification and classification of mechanical components from images using Segment Anything Model (SAM) and Contrastive Language-Image Pretraining (CLIP); (2) reuse profitability assessment through a Recovery Profitability Index (RPI) and Transformer models. Experimental results demonstrate an identification accuracy of 78% for the zero-shot module and up to 91% for profitability classification, highlighting the potential of this approach in the context of circular economy and industrial sustainability.

Keywords: Circular Economy , Transformer Models , Zero-Shot Learning , ICT Components Reuse

This study aims to gather a sustainable understanding of additive manufacturing and other Manufacturing 4.0 approaches like horizontal and vertical integration and cloud computing techniques with a focus on industrial applications. The DfAM will apply 4.0 tools to gather product feasibility and execution, with CAE—FEM analysis and CAM. This publication focuses on the redesign of a vehicle suspension arm. The main objective is to apply innovative design techniques that optimize component performance while minimizing cost and time. The IDeS method and TRIZ methodology were used, resulting in a composite element, aiming to make the FDM-sourced process a viable option, with a weight reduction of more than 80%, with less material consumption and, hence, less vehicle energy consumption. The part obtained is holistically sustainable as it was obtained by reducing the overall labor used and material/scrap generated, and the IDES data sharing minimized rework and optimized the overall production time.

Keywords: additive manufacturing , IDeS , product design , product reverse engineering , TRIZ

The increasing demand for lightweight materials with high mechanical performance has accelerated the development of hybrid composite-metal joints, especially in the transportation industry. Despite their advantages, these joints often present challenges in terms of manufacturability, reliability, and environmental impact. This study evaluates the environmental performance of composite/metal hybrid joints by comparing two scenarios: with and without penetrative reinforcements produced by Additive Manufacturing (AM). A Life Cycle Assessment (LCA) was conducted in accordance with ISO 14040:2021 and ISO 14044:2021 standards, adopting a cradle-to-gate approach. The functional unit was defined to ensure comparability across both scenarios. Primary data were obtained from experimental setups, while secondary data were sourced from scientific databases such as Ecoinvent. Results indicate that the introduction of AM-based reinforcements leads to an 80% increase in tensile strength, enabling a significant reduction in bonding area. This geometric optimization results in a notable decrease in the environmental burden, particularly in terms of global warming potential. Although AM processes involve high energy inputs and specialized feedstock, the structural benefits achieved allow for a more efficient use of materials. Overall, the study demonstrates that performance-driven design through AM reinforcements can offer a viable pathway toward more sustainable structural solutions.

Keywords: Additive Manufacturing , Environmental Performance , Hybrid Joints , Life Cycle Assessment (LCA) , Structural Optimization

The growing demand for sustainable products and the shift towards circular economy models highlight the need for transparent, interoperable, and verifiable data throughout the entire product lifecycle. In the electrical and electronic equipment (EEE) sector, which encompasses common household appliances, the adoption of life cycle engineering tools is limited, which poses a barrier to effective circularity. This study explores the potential of a blockchain-based Digital Product Passport (DPP) as a digital tool to overcome this challenge by enabling the traceability and secure management of product data throughout the entire lifecycle. Tested on a washing machine, the DPP prototype demonstrates how digital passports can enhance lifecycle management, promote sustainability in the EEE sector, and support multi-stakeholder collaboration. The system integrates a standardized Extensible Markup Language (XML) data model and blockchain technology to ensure immutable, verifiable, and transparent data accessible via a centralized platform. The results highlight the DPP's capacity to support decentralized data governance, foster informed decision-making, and facilitate the practical transition toward circular economy scenarios.

Keywords: Digital Product Passport , Electrical Electronic Equipment , Life cycle management