Design for sustainability

Our cultural society has made remarkable advancements in creating digital models that depict the built environment, landscape, and reality. The advent of technologies such as terrestrial laser scanning and drone-based photogrammetry, coupled with sophisticated software capable of processing hundreds of photographs to generate point clouds, has elevated the significance of three-dimensional surveying in documentation and restoration. Point cloud processing and modeling software enable the creation of precise digital replicas of the investigated architecture, which can be scaled down and transformed into physically identical models. Through the export of STL files and the utilization of both subtractive and additive 3D printing technologies, tactile models resembling traditional manually crafted plastics can be obtained. An exemplary study focuses on the Gothic church of Santa Maria Alemanna in Messina, Italy, where laser scanner surveys and 3D prints using various technologies were applied to different parts of the building. The models were produced using a CNC milling machine and a 3D printer for fused deposition modeling. The sustainability of these production technologies was assessed through a Life Cycle Assessment, demonstrating the environmental advantages of additive manufacturing, including the use of materials with high recyclability and lower energy consumption. Additionally, the additive approach helps reduce processing waste.

Keywords: 3D printing , architecture recovery , cultural heritage , digital models , Life Cycle Assessment

Within the road to decarbonization scenario, it becomes increasingly central to analyze the sources of emissions from different perspectives and select the more sustainable design approach for the development of new products. Among many sectors, lightweighting can reduce costs related to energy and fuel consumption. Potentially, it is also possible to reduce emissions, both for air and land transport, especially considering vehicles in the context of electrification and green transition. This paper provides an approach for the quantitative estimation of CO2 emissions along the lightweight design of vehicles components. The approach is based on a Life Cycle Assessment (LCA), which includes aspects ranging from product design and production to the use phase, and possible upgrading and recycling. Two lightweight design strategies are considered, using either conventional or unconventional technologies, which are respectively based on Design for Machining and Design for Additive Manufacturing. These methods can be scaled in high-end sectors, as both are characterized by high flexibility and customization, which allow the implementation of lightweight designs for small batch sizes. An automotive component is used as a case study, performing the product-process design based on Computer-Aided Technologies (CAX) for both approaches. The CO2 assessment is performed, considering all the drivers relating to the stages of the product life cycle. Additive Manufacturing is confirmed as more energy intensive, but the additional mass saving over the vehicle use phase returns emissions reduction compared to the whole life cycle.

Keywords: Computer Numerical Control , Environmental sustainability , Greenhouse gas emissions , Lightweighting , Powder Bed Fusion , Product-process design

New standards (e.g., the EN4555X series) and indices have been issued to include repairability aspects in product design. These indices are very useful in the design phase to characterize the product and to understand the ability of products to be disassembled. The goal of this paper is to address product repairability and ease of disassembly for cooking systems, with a specific focus on induction hobs. A four steps approach was followed encompassing project definition, laboratory tests, disassemblability index calculation, and eco-design actions definition for product improvement. Project definition includes the identification of target components for service/repair purposes, while laboratory test allows retrieval of disassembly data in accordance with EN 45554 standard. The disassemblability index calculation brings to the identification of design criticalities that affect the repairability score providing important insight into the identification of eco-design actions. The implementation of the eco-design actions, when applied in the product development process, will lead to an increment in repairability and serviceability performance for the identified target components.

Keywords: Cooking appliances , Design for repairability , Disassembly , Eco-design , Sustainable design

[No abstract available]

Keywords: additive manufacturing , circular economy , design methodology , digital manufacturing , IoT

The concept of sustainability concerns the ability to satisfy current needs without compromising the possibility for future generations to satisfy their own needs. Over the years this concept turned out to be an essential theme for many industries because of a spread and heightened sensitivity towards environmental protection and social responsibility. Nevertheless, every firm still needs to guarantee the economic viability of its actions and retain its competitive advantage over competitors to remain in the market. This idea corresponds to the triple bottom line approach, according to which the business performance should be monitored from three perspectives, namely economic, environmental, and social. From one side sustainability means the integration of multiple practices, whereas on the other side, the current globalized and competitive economy requires enterprises to combine sustainability with practices of Industry 4.0 to contribute to Circular Economy objectives. The aim is to make choices that improve all three aspects. This work proposes an approach able to involve all three pillars of sustainability and the forefront tools to evaluate them. The case study presents the improvement of the manufacturing process for kitchen furniture. The aim was to create a smart working environment able to increase productivity and mitigate ergonomic risks ensuring a reduced environmental impact. Four parallel manual assembly lines were replaced with one semi-automated line, in which some specific workstations can adapt the product position to the operator's anthropometric measures. The re-design of the workplace allowed both the reduction of out-of-quality pieces and the enhancement of worker well-being. The main results show the achieved optimization for each pillar.

Keywords: Lifecycle analysis , Sustainability , Sustainable manufacturing , Three pillars , Worker well-being

In Industry 4.0, electric vehicles for logistics are widely used, such as shuttles for transporting people and Autonomous Guided Vehicles for industrial equipment. Environmental impact analyses and eco-design guidelines are essential tools in the design phase, where choices have a decisive effect on the entire product life cycle. This work proposes a method and tool aiming to make industrial electric vehicle designers aware of their choices. The proposed tool allows the preventive analysis of the different life cycle phases to highlight the consumption of materials and energy required to optimize the use and the End of Life strategy. Furthermore, it is intended to support the designers who are not provided with much product lifecycle information to obtain an overall picture of how environmental impacts are spread throughout the lifecycle; this will help provide feedback on their choices a pave the way for a more sustainable use phase in the manufacturing plant. It is based on developing a simplified and modular structure where the main product parameters are included for each life cycle phase. The tool is validated in a case study regarding the customization of an Autonomous Mobile Robot, equipped also a robotic arm; the two are connected by a customized structure. The results, which focus both on environmental and economic perspectives, contribute to filling the existing gap in the environmental evaluation of the analyzed product segment; moreover, they highlight how the material and manufacturing phase may be outstanding over the use or End of Life. This is mainly due to the short distances covered during the useful lifetime, which only cover industrial plant areas.

Keywords: Lifecycle analysis , Sustainability , Sustainable manufacturing , Three pillars , Worker well-being

Additive manufacturing is a technology gaining ground in fields where a high degree of product customization is required; in particular, several aspects need to be explored concerning traditional technologies, such as the variety of materials and their consumption. It also remains to be clarified whether these technologies can contribute to the ecological transition when applied in healthcare. This study compares two technologies for producing clear dental aligners: thermoforming and direct 3D printing. The former method thermoforms a polymeric disc over 3D-printed, customized models. The second, more innovative approach involves directly printing aligners using Additive Manufacturing (AM), specifically applying Digital Light Processing (DLP) technology. The study conducts a comparative Life Cycle Assessment (LCA) analysis to assess the environmental impact of these two different manufacturing processes. The research results highlight that adopting direct printing through AM can bring advantages in terms of environmental sustainability, thanks to the reduction in raw materials and electricity consumption. These drops are drivers for the decreased potential environmental impacts across all impact categories considered within the EF 3.1 method. Furthermore, lowering the amount of raw material needed in the direct printing process contributes to a notable decrease in the overall volume of waste generated, emphasizing the environmental benefits of this technique.

Keywords: additive manufacturing , healthcare , life cycle assessment , sustainability

The analysis of motor activity has been revealed to be essential for monitoring dairy cows' behavior, with the main aim of identifying the onset of oestrus in time. Pedometers used for oestrus detection have a current average working life on the market of about 5 years. At the end of that period, devices are disposed of, posing a relevant question regarding environmental sustainability. The present work proposed a method to achieve an eco-design of pedometers compliant with the guidelines of the Green Deal. Specifically, a new thermo-plastic organic compound made of polyamide 66 reinforced with organic hemp fibers (trade name SDS Nylon) was adopted. The feasibility, benefits, and performance of this material were assessed with a major emphasis on strength, lightweight, and surface finish. The material in addition to ensuring adequate chemical and mechanical resistance is biocompatible and recyclable. It assures better animal welfare and reduces both environmental impacts and management costs for farmers. Other innovations introduced in this study consisted of the adoption of a double casing. An external case was conceived with a protective function of the measurement system and fixed to a cow's foreleg by an easy anchor system. An internal case was specifically designed to house the electronic components and to be moved from one cow to another after the pregnancy diagnosis. The solutions proposed in this research will contribute to guaranteeing pedometers a longer lifetime and better recyclability than existing commercial ones, consequently limiting the environmental load derived from their disposal.

Keywords: biocompatible materials for FDM , custom design , digital product optimization , stand-alone smart device , tolerances assignment

This study aims to investigate the thermo-acoustic and hygrothermal properties of innovative panels made of leather waste produced by a bag factory from a circular economy perspective. Their performance was compared with other residual-based insulation panels. The leather scraps were chipped and three boards were fabricated by means of a mold with different compositions, adding adhesive glue. In order to improve the sustainability aspects, a sample was assembled by using a water-based polyurethane glue, in addition to the two panels with vinyl glue. Panels were tested for thermal, acoustic, and hygrothermal performance. Thermal conductivity values in the range of 0.064–0.078 W/mK at 10 °C were measured depending on the composition and the adhesive. A slight thermal performance deterioration occurs when using the natural water-based glue. The samples were characterized by good performance both in terms of sound absorption coefficient (Noise Reduction Coefficient NRC = 0.21–0.28) and Transmission Loss, up to 59 dB values. Water vapor resistance factor values in the 35–48 range were obtained, close to the values of standard materials, such as expanded polystyrene and polyurethane.

Keywords: acoustic performance , bovine leather cutting waste , hygrothermal properties , thermal properties

The paper presents the development of the scaled prototype of an oscillating-arm Wave Energy Converter (WEC), for onshore installation, suitable to be placed above breakwaters. The mechanical architecture is based on a four-bar linkage moved by a floating buoy with alternate heave motion. The mechanical energy is transferred to the electrical rotary generator with the interposition of a mechanical rectifier, to obtain unidirectional motion at higher speed. Since the power take-off system is fully electromechanical, without pneumatic or hydraulic components, the proposed WEC is characterized by high efficiency and reliability. The functional design of the proposed WEC and its control layout are summarized. Finally, the methodology for designing the 1:15 scale model, destined for the preliminary experimental validation, is discussed, and the embodiment design of the model is outlined.

Keywords: Oscillating arm , Scaled prototype , SDG7 , Wave energy converter

Augmented Reality seems a promising tool to provide engaging and effective educational experiences, thanks to its potentiality in stimulating intrinsic motivation, that could influence the learning process and the attitude of the users towards behaviours. This paper presents the Resized Plastic Augmented Reality learning experience, designed on the basis of Dunleavy's framework to provide a systemic overview of the microplastics issue to allow users to understand its mechanisms, educate them about their role in the system and help them to connect this information to their everyday actions.

Keywords: augmented reality (AR) , digital learning , sustainability , user experience

Experience and evaluation research on sustainable products' design is increasingly sup-ported by eye-tracking tools. In particular, many studies have investigated the effect of gazing at or fixating on Areas of Interest on products' evaluations, and in a number of cases, they have inferred the critical graphical elements leading to the preference of sustainable products. This paper is motivated by the lack of generalizability of the results of these studies, which have predominantly targeted specific products and Areas of Interest. In addition, it has also been overlooked that the observation of some Areas of Interest, despite not specifically targeting sustainable aspects, can lead consumers to prefer or appreciate sustainable products in any case. Furthermore, it has to be noted that sustainable products can be recognized based on their design (shape, material, lack of waste generated) and/or, more diffusedly, information clearly delivered on packaging and in advertising. With reference to the latter, this paper collected and classified Areas of Interest dealt with in past studies, markedly in eco-design and green consumption, and characterized by their potential generalizability. Specifically, the identified classes of Areas of Interest are not peculiar to specific products or economic sectors. These classes were further distinguished into “Content”, i.e., the quality aspect they intend to high-light, and “Form”, i.e., the graphical element used as a form of communication. This framework of Areas of Interest is the major contribution of the paper. Such a framework is needed to study regularities across multiple product categories in terms of how the observation of Areas of Interest leads to product appreciation and value perception. In addition, the potential significant differences between sustainable and commonplace products can be better investigated.

Keywords: areas of interest , brand , eco-design , eco-labels , eye tracking , green consumption , product description , sustainable products , value perception

Sustainability-related information affects people's choices and evaluation. The literature has made significant efforts to understand the best ways of delivering this kind of information to shape consumer behavior. However, while most studies have focused on packaged products and direct information provided through eco-labels, preferences could be formed differently in other design domains. The paper investigates the effect of the perceived amount of indirect information on the evaluation of an architectural artefact. A sample of 172 participants visited a locally produced mobile tiny house, made with a considerable amount of sustainable materials. The same participants answered a questionnaire about their perceived knowledge, quality, appropriateness and sustainability of the tiny house. The general level of knowledge of the tiny house was used as a proxy of the amount of indirect information received. Although the knowledge of the tiny house was generally low, ratings regarding the other dimensions were overall extremely positive. In particular, no evident relation was found between knowledge of the tiny house and sustainability, while the latter is significantly linked to quality aspects. These outcomes deviate from the evidence from other studies; this might be due to indirect vs. direct information and the peculiarity of the study carried out in the field of buildings. The gathered demographic and background data of the participants make it possible to highlight the role played by gender and age in affecting the evaluations, but the absence of a significant impact of experience in the field, education and origin. The results are compared with findings related to the evaluation of sustainable products and green buildings in particular.

Keywords: awareness , background , buildings , consumer behavior , eco-design , indirect information , sustainability

This exploratory work aims to understand which elements of a building mostly attract visitors' attention. An experiment was conducted to allow participants to visit a prototype tiny house while wearing eye-tracking glasses. Identified gazed elements of the prototype were selected and the corresponding dwell times used as variables. The limited dwell times on structural elements show that they can be easily overshadowed by other features present in the building. This leads to a design problem when the novelty and the quality of a new product, markedly a building, reside in the materials used.

Keywords: architectural design , eye tracking , human-centred design , interaction design

Product design is an activity that must be supported by information in order to allow designers to conceive solutions to real problems that do not introduce further issues, first of all, environmental concerns. Axiomatic design is an approach that provides the possibility to check whether a design solution is functionally valid and it can also be extended considering eco-design elements. In a synthetic representation of 1D and 2D arrays, it can inform designers about the level of sustainability of the product on which they have been working on since the first phase of design when they start to embody functionalities by introducing real components, and first assemblies appear. To achieve this task, the domains considered in the original formulation of Axiomatic Design have been revised, and a new domain has been introduced. This allows designers to take into account all the phases of product life and improve design solutions to avoid introducing structures, components, and functionalities that might be the cause of environmental problems. The paper describes such new mapping among domains and applies it to design a daily life device. The contents of the new data structure will be presented and discussed.

Keywords: Axiomatic design , Design matrix , Mapping among domains , Sustainability matrix , Sustainable products design

The lifecycle of a product is getting shorter in today's market realities. Latest developments in the industry are heading towards achieving products that are easy to recycle, by developing further technological advances in raw materials ought to include input from End of Life (EOL) products so a reduction of natural harm could be achieved, hence reducing the overall production environmental footprint. Therefore, the approach taken as a design for environment, a key request nowadays in order to develop products that would ease the reverse manufacturing process leading to a more efficient element recycling for later use as spare parts or remanufacturing. The methodology proposed compares three probable disassembly sequences following a comparison of literature-found procedures between genetic algorithms and as a “state space search” problem, followed by a hybrid approach developed by the authors. Time and evaluation of these procedures reached to the best performing sequence. A subsequent augmented reality disassembly simulation was performed with the top-scored operation sequence with which the user is better able to familiarize himself with the assembly than a traditional paper manual, therefore enlightening the feasibility of the top performing sequence in the real world.

Keywords: closed loop , Disassembly , genetic algorithms , metaheuristic method , optimization , particle swarm optimizer

Industry 4.0 (I4.0), through the digitalization and interconnection of manufacturing processes, can offer opportunities to improve production systems' sustainability. Despite the increasing number of scientific review papers related to I4.0 and production sustainability, most approaches and tools for sustainability evaluation lack of a tangible implementation framework. The paper presents a framework that originated from the plant metabolism concept, a simplified version of industrial metabolism. It is based on Energy Material Flow Analysis (EMFA) and Life Cycle Assessment (LCA) tools for production plants' economic and sustainability assessment, using the I4.0 enabling technologies. A Multi-Criteria Decision Making (MCDM) method combines the two sustainability pillars for aiding companies in optimizing their production processes towards a reduction of energy/material flows. The combination of EMFA, LCA and MCDM tools into a plant metabolism-based model is the main novelty of this paper. The framework consists of three main phases. The first phase allows to model the manufacturing system by defining the plant layout, the assets, and the input/output flows. The second phase allows gathering information from the manufacturing plant to assess environmental and economic Key Performance Indicators (KPIs) following the LCA principles. The third phase consists of post-processing results, minimizing specific KPIs for establishing the optimal production scenario. A washing machine plant has been chosen as a case study to demonstrate the proposed method's capability in authentic contexts. Besides, the effectiveness in supporting companies in the analysis, identifying criticalities, and the proper energy and material flows management of production plants has been verified. Plant managers could use this framework for managing the production plans. From the scientific standpoint, the proposed method positively contributes to integrating the existing state of the art studies concerning the I4.0-related framework for the sustainability assessment and energy/material flows minimization of production systems.

Keywords: Energy/material flows , Industry 4.0 , Life cycle assessment , Manufacturing plant , Plant metabolism , Sustainable manufacturing

One of the main aspects to increase the useful life of ErP and reduce waste generation is the product repairability. Key factors in assessing the ability to repair a product are the ease of disassembly, and the use of repairability indexes (i.e., eDiM, French repairability index, RSS, etc.). The goal of this paper is to retrieve eco-design guidelines analyzing the product repairability of target components belonging to four different types of electric ovens. The analysis adopts as baseline the report of the Joint Research Centre and the European standard EN 45554. Results provide interesting insights concerning the identification of disassembly issues and the mitigation of these hotspots through eco-design guidelines retrieved by the analysis of repairability.

Keywords: circular economy , cooking appliances , design for disassembly , design for repairability , disassemblability index , disassembly , eco-design , oven , repairability

Traditional assembly processes such as screw fastening and riveting are increasingly being replaced by new processes such as adhesive bonding. Life cycle performance including fatigue and durability are critical, for which surface activation techniques are often used with the aim of improving both mechanical and life cycle performance. Within this context, the present paper aims to investigate the life cycle performance of adhesive bonding in relation to engineering polymers considering four surface pre-treatments: mechanical, chemical, plasma, and laser activation. The work focuses on two key aspects: (i) mechanical characterization of fatigue performance by assessing the useful life of joints, and (ii) environmental analysis through Life Cycle Assessment (LCA). The outcome of this study provides important insight into the development of laser and plasma technologies as sustainable surface activation methods for polymer joining methods. The substitution of traditional joining methods (i.e., bolting, riveting) with adhesive bonding will allow reductions in overall product weight to be achieved.

Keywords: adhesive bonding , assembly , design for assembly , environmental impact , fatigue , LCA , polymers , surface activation

According to the European energy consumption reports, the highest energy consumption in residential sector is due to space heating, followed by water heating. Generally, the product used to warm water in residential building is the boiler where heat exchanger is the core of the system. The paper aims to develop a novel concept of heat exchanger by following eco-design actions retrieved by the analysis of life cycle performance. Several eco-design actions were put into practice to reduce the environmental issues in each phase of the life cycle. Concerning the materials and manufacturing phase, a novel design based on different material (i.e., stainless steel) was developed to replace a mix of materials (i.e., copper and aluminum alloy). Concerning the use phase, the overall product efficiency was increased allowing important savings in terms of gas/energy consumptions. Finally, concerning the end-of-life phase, brazing processes was replaced by other joining processes to increase component's disassembly and varnishing process was avoided due to the better corrosion resistance performance of the stainless steel. The new heat exchanger shows better environmental performance in each Life Cycle Assessment indicator, saving more than 40% in CO2 emissions (GWP) in the whole product life cycle.

Keywords: Ecodesign , Energy consumption , Heat exchanger , LCA , Life cycle