Design for sustainability

The in-situ restoration and conservation of submerged archaeological assets aim to ensure their preservation and transmission to future generations. The deterioration of these artifacts is primarily caused by biofouling and water quality. Depending on the extent of degradation, an initial cleaning phase is typically followed by a consolidation phase. To date, no dedicated tools have been developed for this consolidation process, and manual or pneumatic tools are commonly used, often leading to various inefficiencies. To address this issue, the paper proposes a novel injector device specifically designed to enhance the efficiency and effectiveness of the work carried out by underwater restorers and archaeologists for the consolidation and conservation of the submerged archaeological remains. The proposed device is a cordless mechatronic instrument that enables the precise application of consolidating mortars in underwater environments. Additionally, it features an innovative mortar storage system with an automatic rotating cartridge, which significantly improves the efficiency of the consolidation process. The paper presents the modular architecture, technical solutions, and key features of the proposed injection underwater device.

Keywords: product design , SDG 13 , SDG 14 , SDG 9 , underwater cultural heritage , underwater injector device

Limited research has explored the delivery of sustainable design in higher education globally. Therefore, the aim of this paper is to investigate educational practices on the topic. Through an online survey, we investigated numerous aspects of units of study exposing topics related to sustainable design with a focus on contents, teaching methods and educational objectives. The survey was accessed by almost 400 educators in the field of sustainable design. The data show that a variety of teaching methods are used, with a critical role played by project-based learning in addition to traditional lectures. Most respondents rated all investigated intended learning outcomes as relevant or very relevant. In terms of contents and methods treated by the respondents, product eco-design and design for X are the most frequently taught methods. Educational approaches and teaching objectives are poorly affected by the discipline of the degree in which units of study are taught. In terms of contents, design degrees include approaches to sustainable design at the spatio-social level more frequently than engineering degrees do.

Keywords: higher education , intended learning outcomes , project-based learning , survey , sustainable design

Additive manufacturing processes could reduce environmental impacts by optimizing the material distribution and achieving lightweight products. The sustainability of the additive processes can be further improved by using recycling methods. The most used practices are reusing metal powders for multiple builds and recycling components throughout the additive manufacturing process to make recycled powders. This paper addresses the current state of the art recycling practices regarding the use of metal powders in Laser-Powder Bed Fusion process propose an approach to consider the environmental impact of the product during the design phase. The approach considers a mix of virgin, reused, and recycled powders as the material input. The design optimization workflow and Life Cycle Assessment provide useful tools to achieve feasible and sustainable solutions.

Keywords: DfAM , L-PBF , Laser-Powder Bed Fusion , Recycled powders

Directed Energy Deposition is mainly adopted for the construction of large parts and structures or the reparation of worn and damaged components, but also in Hybrid Manufacturing systems, to combine features of different technologies. An additional emerging application is the Remanufacturing of existing components by integrating further features and materials to enhance products' functionality. Nevertheless, residual stress and strain are among the most relevant drawbacks since thermal gradients and cooling rates are more intensive compared to other Metal Additive Manufacturing processes. With the aim to define the build strategies (e.g.: tool paths and scanning patterns) for multiple depositions on actual existing components and mitigate the substrate deformation, this work is focused on the laser-based Direct Metal Deposition process design and optimization. To find the best trade-off between process efficiency and product quality, the goal is achieved identifying the build strategies (i) to guarantee the expected product requirements and (ii) to provide functional and assembly requirements. The case study is the Additive Remanufacturing of an automotive component, requiring a functional tolerance control, which implies to contain process-induced distortion. The build process is assessed through Finite Element thermo-mechanical simulations of 316L deposition, cooling, and unclamping steps. The effects of factors as the deposition strategy, orientation, direction, and sequence, are studied through a Design of Experiments approach. The model maximum displacement is the primary response, and the build time is the secondary one.

Keywords: AISI 316L , Finite element method , Laser metal deposition , Process optimization , Process simulation

Life cycle engineering is a crucial design methodology to support optimized design choices in the context of ecodesign, particularly for components manufactured with novel technologies such as additive manufacturing. This study presents a systematic literature review on the topic, analysing 87 publications following the PRISMA framework. The review explores the environmental and economic life cycle implications of additive manufacturing in relation to the technological features and engineering design aspects. Additionally, it shows existing frameworks for integrating ecodesign into sustainability assessments of additive manufacturing and the development of ecodesign guidelines. From an engineering perspective, these technologies introduce several advantages enabling the creation of lightweight, multi-functional, and performance-optimized components. However, challenges related to high energy consumption, material preparation, and variability in life cycle impacts need to be addressed with dedicated life cycle analysis to ensure environmental and economic sustainability. Existing methods for integrating ecodesign into life cycle assessment are fragmented, with limited frameworks combining environmental and economic aspects. Emerging approaches, such as automated life cycle assessment tools, show promise but remain underexplored. Ecodesign guidelines emphasize well-known strategies such as material optimization and waste reduction. Nonetheless, translating these guidelines into standardized practices remains a challenge.

Keywords: 3D printing , Design for Sustainability , Ecodesign , LCA , LCC , Life Cycle Assessment , Life Cycle Costing

Household appliances are no longer a luxury but a need in every household. The excessive use of the devices has led researchers to focus on their influence on the environment. This paper investigates the life cycle performances of three different types of freestanding kitchens used in Europe with different hob technologies (electric, gas and induction) using the Life Cycle Assessment method. The work provided data collected (Life Cycle Inventory) for each model of the freestanding kitchens manufactured in the European market. The functional unit used for the comparison of the three types of freestanding is "the amount of energy used to make 2 meals a day for a year". To evaluate the environmental impact of the appliances a dedicated software was used (i.e., SimaPro). A comparison between the environmental impact results allows the users to choose the most sustainable appliance in accordance with their need. Focusing on Global Warming Potential impact, the ranges adopted induction hob shows a higher impact results during the raw Materials and Manufacturing phase compared to the other ranges. On one hand, the environmental impact results from cradle to gate concerning the raw materials extraction and manufacturing process show that the most critical aspect is related to the use of metals in large parts such as the cavity and structure of the products. On the other hand, the environmental impact regarding the use phase shows different results depending on the source of energy in the country where the freestanding kitchen is used. The outcome of this work can be a reference to enhance the sustainability of these products in the future. © 2025 Elsevier B.V..

Keywords: Design for Sustainability , household appliances , LCA , ranges

Repairability plays a key role in promoting a circular economy and extending the lifespan of products. Therefore, the European Commission has adopted various related regulations to promote sustainability and achieve the goals set in the European Green Deal. As part of these efforts, initiatives have been placed to encourage manufacturers in developing reparable products by the development of new standards, such as EN4555x series, as well as new energy labels, e.g., for smartphones and tablets, which will come into effect in June 2025. To better align with these recent legislative developments, designers need engineering guidelines to create easily repairable products from the outset of the design process. Therefore, the objective of this article is to provide technical solutions to increase repairability of functional modules, based on analyses conducted on various household appliances. For this research, five different categories of appliances are analyzed from a repairability perspective: cooker hoods, hobs, combo-hobs, ovens, and freestanding kitchens. Common functional modules across all the analyzed appliances are identified. By applying the EN45554 standard and conducting manual disassembly tests on physical products, critical issues in these modules are identified, as well as smart design solutions. Based hereon, design solutions are proposed for each functional module commonly employed in household appliances. This comprehensive study aims to offer practical insights for designers, helping them to incorporate repairability into their design processes and ultimately contribute to a more sustainable and circular economy. © 2025 Elsevier B.V..

Keywords: Design for Repairability , Disassembly , Eco-design , Houshold appliances , Sustainable Design

The environmental consciousness of energy-related products that are necessary for everyday life is increasing due to the needs and requests for these products. This paper investigates the environmental load of a freestanding gas range, using the life cycle assessment (LCA) method. The work provided data collected (life cycle inventory) for this specific model of the freestanding cooker manufactured in the European market. The impact assessment specified in this paper was elaborated using a dedicated software tool (i.e., SimaPro) to evaluate the impact of the different modules of the freestanding kitchen during the life cycle phases excluding the use phase and end-of-life. The environmental impact results show that the most critical aspect is related to the use of metal materials in the production of large items such as the cavity and body of the freestanding kitchen, on top of these materials are stainless steel and carbon steel. In addition to the manufacturing process used for these modules. The outcome of this work allows to compare this cooking appliance to other cooking appliances present on the market, providing interesting data for the development of future eco-design actions.

Keywords: Environmental impact , LCA , Sustainable design

Self-tapping screws are essential components in the assembly of sheet metal for mechanical products. These screws, thanks to their ability to create secure and durable joints with minimal preparation, are commonly used in many industries such as consumer electronics, home appliances, automotive, and industrial equipment. In this study, experimental studies have been performed on mechanical joints of sheet metal parts that employed self-tapping screws. Disassembly time has been assessed through several tests, considering variations in screw geometric features (head type, diameter, pitch, and length), the use of alternative disassembly tools (manual and electrical screwdriver), and different sheet metal thicknesses. In relation to the screw geometric features, the disassembly time was mostly affected by the combination of diameter and length (and consequently of the pitch) with limited influence of sheet metal thickness. The outcome of this study drives the design of mechanical joints for sheet metal applications in several products, providing design for disassembly guidelines of reversible joints employing self-tapping screws.

Keywords: Circular economy , Design for Disassembly , Mechanical fastening , Metal joint , Sustainable products

Snap-fits are fasteners that join and separate components without screws, adhesives, or rivets, streamlining mechanical connection and disassembly in several applications, as electric appliances. This study focuses on evaluating manual disassembly time for U-shaped snap-fits, analyzing various geometric characteristics (tab width, length, inclination, and the number of locking tabs). The tests showed that slotted housings ease disassembly, with tab width and length having the most significant impact on time, while slope and lug count had minimal influence. The findings provide a basis for creating a database to support future design for disassembly tasks, improving circularity potential in many industrial sectors.

Keywords: Circular economy , Disassembly time , Electrical appliances , Snap-fit , U-shaped

The Eco-design for Sustainable Products Regulation has introduced the Digital Product Passport (DPP) as a key tool for tracking and promoting the sustainable development of products. Despite the growing interest in DPPs, standardized models are yet to be established, with only experimental alternatives available from various organizations. Moreover, no existing model fully exploits the data, as conducting a life cycle assessment (LCA) still necessitates acquiring additional data from various life cycle stages. This study aims to bridge this gap by developing a fully decentralized DPP prototype specifically for the Electrical and Electronic Equipment (EEE) sector. The research begins by defining a tree-structured hierarchical model for data collection and management, aligning with regulatory standards. The prototype's implementation employs an eXtended Markup Language (XML) file for data digitalization and blockchain technology to ensure secure data sharing and storage. Tested on a household appliance, the DPP prototype demonstrates how digital passports can enhance product lifecycle management, driving sustainability in the EEE sector and supporting the implementation of circular economy scenarios.

Keywords: Blockchain , Digital Product Passport , Eco-design , Electrical Electronic Equipment , Lifecycle Management

Additive Manufacturing (AM) is a promising technology that fosters innovation and increases designers' freedom. Considering the sustainability performances, AM technologies seem to have significant potential since they produce reduced or near-zero waste. However, the advantages depend on the specific application, especially in the context of metal AM, and need to be evaluated from a lifecycle perspective. The present paper proposes a simplified model for the economic and environmental sustainability assessment of the metal Selective Laser Melting (SLM) process. The model is grounded on mapping the main phases and related energy/materials flows, included in the lifecycle of an AM manufactured part (raw material, manufacturing, use end of life, transport). The preliminary tests, realized in the context of a motorbike application, confirmed that the lifecycle perspective of the model is an essential feature to guide the decision-making both during the design process and in later stages of product development.

Keywords: Additive Manufacturing , Economic Assessment , Environmental , Lifecycle Model , Selective Laser Melting

Electrical and electronic equipment (EEE) are essential products that support everyday activities such as washing clothes, storing food, and cooking. However, the limited application of life cycle engineering approaches in this sector creates a significant barrier to adopting circular economy models. To address this issue, this paper proposes a platform, called PiCo2RAEE, developed to promote the management of EEEs throughout their entire life cycle. The platform aims to facilitate coordinated collaboration among critical stakeholders, including designers, consumers, and end-of-life management entities. PiCo2RAEE integrates three main modules: (i) Design for Disassembly (DfD) tool to suggest design solutions able to simplify the disassembly of key components; (ii) Digital Product Passport (DPP) for tracking and sharing critical information among stakeholders along the value chain; and (iii) Second Life tool to encourage the exchange and reuse of knowledge, expertise, products, components, and materials. This platform enables the transition to circular economy practices by emphasizing durability, recyclability, reparability, and remanufacturing of EEE products. Improving these attributes, PiCo2RAEE supports the sustainable use of resources, reduces waste, and promotes the implementation of green and long-lasting solutions in the EEE industry. Its collaborative approach ensures that all parties involved in the product life cycle contribute to achieving a more sustainable and circular economy.

Keywords: Circular economy , Ecodesign , Electrical and electronic equipment (EEE) , Life cycle management , Product passport

Additive manufacturing (AM) is currently considered one of the most promising technologies for fostering innovation in the industrial sector, specifically in product design. Considering the non-subtractive nature of AM processes, in first approximation, they all seem to be environmentally sustainable since they lead to a null or at least reduced quantity of scraps. However, the peculiarities of such technologies, such as the specific input materials (e.g., metal powders, polymer filaments) or the low productivity, make the situation more complex, not so homogeneous in all the cases, and strongly dependent on the process and product parameters. In this complex scenario, the present paper aims to investigate the current state of the art regarding adopting Artificial Intelligence (AI) and Machine Learning (ML) toward the eco-design for AM. Following the PRISMA methodology, a set of 19 scientific papers were analysed. Papers were grouped according to the benefits (improvement of quality and reduction of energy, waste and defects) and design opportunities (definition of shapes and selection of materials) that AI and ML potentially provide. The discussion of the results presents the most relevant research and development opportunities for scholars and companies.

Keywords: Additive manufacturing , Artificial intelligence , Eco-design , Literature review , Sustainable design

In the Industry 5.0 paradigm, where human-centricity and sustainability are paramount, there is a pressing need for a comprehensive framework to evaluate the social sustainability of products through the lens of employee well-being. This paper proposes a human-centric product sustainability index specifically tailored for this purpose. The index incorporates a multidimensional assessment of product processes, utilizing various indicators based on standardized methods. Sensor-based approaches enhance the objectivity and accuracy of the analysis. By providing a quantitative and standardized measure, the index facilitates informed decision-making, promotes responsible product design and manufacturing, and reduces occupational health risks.

Keywords: Human-centric manufacturing , Industry 5.1 , Occupational health , Social sustainability

This paper presents the method and architecture of a novel software tool designed to support energy efficiency evaluation and environmental sustainability assessment in the industrial sector. By integrating principles from Lean Management (LM), specifically Resources Value Mapping (RVM), the tool enables users to identify energy inefficiencies and correlate energy use with production processes, concurrently providing Carbon Footprint (CF) assessment. The proposed approach allows companies to analyze energy flows through key indexes used as KPIs for energy performance quantification. Furthermore, the tool's flexible data input capabilities make it adaptable across different industrial settings. The tool was tested and tailored for the Off-Site Construction (OSC) sector in the Italian geography, where it demonstrated its utility in managing supply chain energy interactions and highlighting critical inefficiencies both at the energy and sustainability level, aligning with the European Union's Net-Zero ambitions. © 2025 Elsevier B.V..

Keywords: Carbon Footprint , Energy efficiency , Resources Value Mapping

Due to growing concerns about environmental sustainability and rising energy prices, energy efficiency-oriented design is becoming increasingly important in the industrial sector. The most optimal energy efficiency decisions are made early in the design process. During the initial design phase, the design team must evaluate energy implications in a timely and approximate manner. Consequently, a technique is needed that can quickly and with few parameters evaluate the energy effect of a product during the conceptual design phase. Machine Learning (ML) has established itself as a field of study in industrial research. Approximating the energy effect using high-level data is accelerated by incorporating machine learning into the conceptual design. This paper suggests a way to create a parametric model to evaluate the energy impact of parts made on lathes in the early design stages. The results of the predictive model could be used to determine the energy efficiency indexes of an industrial plant. © 2025 Elsevier B.V..

Keywords: Energy impact , Machine Learning , Manufacturing model

The contribution of the present work is to ease lifecycle design through more accurate Life Cycle Assessment results, still maintaining linearity and computation time and complexity low. The paper presents a method and application to accurately and objectively assess the environmental impact of products, considering how the considered flows (input/output) can change over time (i.e., technology evolution, use profile). Therefore, the analysis becomes dynamic, oppositely to the traditional Attributional Life Cycle Assessment. It introduces a temporal dimension, acknowledging that the analyzed system environmental performance evolves due to multiple causes, that are classified in five main categories: design, technology, fade, user and aside, yet maintaining linearity in calculation and the focus solely on the product. The application to the case of a laptop and the relative sensitivity analysis outlines how important but heavy it is to consider factors that can alter the flows entering and exiting the system boundaries. Future work will extend the application of the approach to non-energy-related products.

Keywords: dynamic impact assessment , Lifecycle design , product environmental impacts

Environmental impact assessment during the initial design phases is essential to guide designers towards more eco-sustainable choices. This paper proposes a method to parameterize production processes considering the energy and material contributions involved. The case study focuses on the welding process of a component of a steam turbine. The goal of the method is to obtain functions that, parameterized with respect to the mass of the finished component, determine the consumption of the process. The functions are obtained considering different dimensionally scaled components. Commercial software was used to calculate the process times and mass flows.

Keywords: Lifecycle design , Parametric model , product environmental impacts

In recent years, maritime industries have focused their attention on hydrofoils as one of the main technologies for the development of eco-sustainable solutions in the field of boating. The aim of the current research was to analyze the front wing of a Kohlkida class hydrofoil and to describe the methodology employed for the reconstruction of the 2-D airfoils by means of photogrammetry. Considering the limitations of the photogrammetry methods, some sections were extracted from the model. The airfoils were properly scaled and first compared with the model obtained by means of a laser scanner. Under the operating condition of the hydrofoil and with the use of Reynolds-averaged Navier–Stokes simulations, the behavior of the airfoils was simulated, allowing us to verify how the geometric differences due to the photogrammetry approach affect the fluid dynamics, in comparison to the model obtained from laser scanning. The proposed methodology led to a geometry reconstruction with adequate accuracy for the identification of both the characteristic curves for the lift and drag coefficients with a maximum error of 6% in the angle-of-attack range investigated in the study, also highlighting fluid dynamics problems that characterize this type of airfoils with a flat bottom and a knife-sharp leading edge.

Keywords: Computational fluid dynamics (CFD) , hydrofoil design and modeling , laser scanning , measurements , photogrammetry , reverse engineering