Design for sustainability

The electrification of non-road mobile machinery is advancing to enhance sustainability and reduce emissions. This study investigates how to maximize the efficiency of the retrofitting of a material handler from an internal combustion engine to a battery-powered electric motor, while keeping the hydraulic system unchanged. Using a previously validated model, this study proposes three control strategies for the electric motor and hydraulic pump to enhance efficiency and performance. The first control strategy optimizes hydraulic pump performance within its most efficient displacement range. The second strategy maximizes powertrain efficiency by considering both efficiencies of the electric motor and hydraulic pump. The third strategy uses a servo-actuated valve to adjust the load-sensing margin and exhibits energy savings up to 14.2% and an 11.5% increase in efficiency. The proposed strategies avoid complex optimization algorithms, ensuring practical applicability for small- and medium-sized enterprises, which often face cost constraints and limited scalability.

Keywords: electrification , energy saving , hydraulics , load sensing , non-road mobile machinery , off-highway

With the advent of additive manufacturing (AM) and advanced fiber-reinforced composites, integrating orthotropic material behavior into the design phase is increasingly essential. Unlike isotropic assumptions typically used in topology optimization (TO), orthotropic materials exhibit direction-dependent properties that significantly impact mechanical performance, especially in the build direction due to AM layer-wise construction. Traditional workflows often separate design and manufacturing stages, leading to suboptimal structures when material anisotropy is ignored. This study proposes a design framework that embeds orthotropic elasticity into TO using the Solid Orthotropic Material with Penalization (SOMP) method. Material orientation, directly linked to part build direction, is treated as a variable influencing both product performance and process sustainability. A flat lamina case study illustrates how different fiber alignments affect mechanical behavior, while a second case involving a Formula SAE brake pedal demonstrates the feasibility of redesigning metal parts for composite AM. Key performance indicators (KPIs) are evaluated across material orientations to assess trade-offs in structural performance and manufacturing efficiency. Co-optimizing material orientation and geometry would allow to enhance stiffness-to-weight ratios and reduce waste and post-processing. The findings demonstrate the feasibility of further integrated product and process optimization using topology optimization of orthotropic materials.

Keywords: 3D Printing , CFRP , Design for Additive Manufacturing , Finite Element Method , Material Anisotropy , Sustainable manufacturing

The integration of Human Body Digitization Technologies (HBDTs) into the fashion industry presents a transformative approach to personalize garment design and production while addressing sustainability challenges. This study investigates the feasibility, accuracy, and effectiveness of various measurement techniques, including traditional manual methods, 3D body scanning, and smartphone applications, to capture anthropometric data. A mixed-methods approach was employed for a pilot study involving 15 participants to assess the technical reliability of HBDTs in comparison to established garment manufacturing standards. Findings indicate that while traditional measuring techniques suffer from significant variability and inaccuracy, 3D scanning technologies demonstrate a higher degree of reliability, yielding measurements suitable for on-demand garment production. However, smartphone applications, while convenient, often lack precision and completeness in capturing essential dimensions for garment fitting. The study reveals that the successful adoption of HBDTs requires a comprehensive understanding of the digital anthropometric pipeline, necessitating interdisciplinary skills among fashion practitioners. Key challenges include operator errors, digital avatar optimization, and software limitations. Despite this, HBDTs show strong potential to improve garment fit, reduce waste, and support inclusivity. The study underscores the need for further research and highlights the value of advanced measurement methods for a more human-centric and sustainable fashion industry.

Keywords: 3D body scanning , Body sizing , Digital avatar , Fashion design , Sustainability

According to the European energy consumption reports, the highest energy/fuel consumption in the residential sector is due to space heating, followed by water heating. Generally, the product used to warm water in residential buildings is a boiler system where a heat exchanger is the core of the system. The paper provides a Life Cycle Assessment analysis of a traditional heat exchanger used in domestic boilers with the aim to identify critical aspects and environmental hotspots for the development of a novel concept of the heat exchanger. The methodology used to collect eco-design guidelines from the Life Cycle Assessment analysis is proposed within the paper. Several eco-design actions were put into practice to reduce the environmental issues in each phase of the life cycle from the materials used, the manufacturing processes as well as the product geometry to increase energy efficiency during the use. Concerning the materials and manufacturing phase, a novel design based on a different material (e.g., 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 consumption, by the adoption of a novel design (e.g., spiral pipe). The new heat exchanger design shows better environmental performance in each Life Cycle Assessment indicator, saving more than 40% in CO2 emissions (Global Warming Potential) in the whole product life cycle.

Keywords: Eco-design , Energy Consumption , Heat exchanger , LCA , Life Cycle Engineering , Sustainable design

The concept of Industry 5.0 (I5.0) promotes the human-centricity as the core value behind the evolution of smart manufacturing systems (SMSs), based on a novel use of digital technologies in the design and management of modern industrial systems to take up the socio-technical challenges. In this context, the paper proposes a Smart Manufacturing Systems Design (SMSD) framework enabling I5.0, based on the human-automation symbiosis. Thanks to an ‘Augmented Digital Twin' (ADT) able to integrate and digitize all the entities of the factory (i.e. machines, robots, environments, interfaces, people), AI-driven applications can be built to support the user domain and make people and machines co-evolve thanks to a systematic data sharing between physical and digital assets (e.g. digital twin, virtual mock-ups, human-machine interfaces), optimizing factory productivity and workers wellbeing. In this framework, machines and humans can both generate knowledge and learn from each other, generating a virtuous co-evolution, supporting the understanding of the human-machine interplay and the creation of an effective collaboration between people and SMSs. The framework was conceived and validated involving four industrial companies, belonging to diverse sectors, interested in overcoming the current limits of I4.0 lines by including the human factors for future SMS management.

Keywords: augmented digital twin , human-automation symbiosis , Industry 5.0 , Operator 4.0 , Operator 5.0 , smart manufacturing systems

Sustainability is fundamental in the field of additive manufacturing (AM) for improving eco-consciousness and driving evolution toward environmentally responsible production methods. Compared to traditional manufacturing processes, AM technologies can be more resource-efficient and offer innovative solutions for creating eco-friendly processes and products. Nevertheless, there is significant potential for improvement in additive manufacturing sustainability. The key factors driving this improvement include design optimization and increased awareness. Designers and engineers can create designs that optimize material efficiency and reduce support structures. Raising awareness and educating stakeholders about the environmental benefits of AM can promote responsible choices throughout the industrial process. The development of a tool to assess the environmental impact of AM processes could be a significant contribution to advancing sustainability in the AM field. The EcoPrintAnalyzer, introduced as a complementary plugin for UltiMaker Cura, offers data on the equivalent carbon dioxide footprint and energy consumption in material extrusion additive manufacturing. This tool facilitates informed decision-making regarding materials, designs, and settings, enabling users to optimize their AM processes for reduced waste and enhanced energy efficiency. Beyond aiding decision-making, the EcoPrintAnalyzer fosters environmental consciousness and encourages the adoption of sustainable practices within the AM ecosystem. The efficacy of the tool is demonstrated through the 3DBenchy model case study, showcasing its intuitive interface and seamless integration within the AM process workflow for immediate and comparative environmental impact assessments across different process configurations.

Keywords: additive manufacturing , carbon footprint , eco-design , material extrusion , sustainability assessment tool , sustainable development , UltiMaker Cura

Robotic cells are complex mechatronic systems whose final performance is determined by the interaction of the control logics with the mechanical behavior of the process. In this context it is fundamental to develop engineering methods and tools for the virtual prototyping of the cells that emulate both contributions. With such mechatronic digital models, it would be possible to replicate the real behavior of the systems and to optimize the cell productivity, up to building complete digital twins. This paper proposes an engineering method to develop realistic Virtual Prototypes of robotic cells including their geometry, operating logic, performance, and physical behavior. A case study on a robotic cell composed of two anthropomorphic robots for the flexible process of automatic assembly of industrial parts is presented to demonstrate the approach.

Keywords: Digital twin , Physics-based simulation , Robotic assembly , Virtual prototyping

The controlled provision of stimuli during idea generation is considered effective to boost creativity in early design phases. As the interest for sustainable product development and circular design is growing, this paper represents a first attempt to explore the use of inspiration sources in sustainable design. The provision of stimuli ascribable to sustainability and the introduction of environmental objectives in design briefs were supposed to increase novelty and compliance with Circular Economy principles in generated ideas. A design experiment involving 34 junior designers was set up to the scope; the participants' individual creativity was assessed too. The outcomes reveal that the sustainability clues present in stimuli and design briefs failed to increase the circularity and novelty of the generated ideas; the same applies to the combination of novelty and creativity. A role is seemingly played by individual creativity, although no significant effects could be demonstrated statistically. A possible reason for these results could be the spontaneous orientation of the youth toward sustainable principles, which makes the inclusion of environment-related hints unnecessary. While creative and sustainable design have not found a shared strategy despite the expected benefits, the use of stimuli was unsuccessful in this research to find a common ground.

Keywords: circularity , junior designers , Novelty , stimuli , sustainable development

The concept of a novel sanitization device specifically designed for helmets used in bike share services is presented in this scientific work. The system uses ozone, a powerful oxidizing agent, to completely remove dust and bacteria from the helmet surface. Throughout the development process, special attention has been paid to the dual initial goals of efficacy in removing dirt and batteries, as well as ease of use related to the device's safety. In fact, today's sharing services are rarely capable of providing adequate disinfection of the tools, which is especially troubling given the most recent years of pandemic caused by Covid-19. The invention of the ozone-based sanitization device addresses the growing concern about hygiene and safety in bike share services. Furthermore, due to its portability and ease of use, the device is a cost-effective and viable solution for use in a variety of settings. A significant contribution to the advancement of sanitization technology and public health is expected with this work.

Keywords: Eco-sustainability design , Hygiene , Innovation , Safety , Sanitation system , Sharing services

The adoption of lightweight materials in engineering applications has become more popular over recent years, with adhesives replacing traditional joining methods such as bolts and rivets. Adhesion science and related technologies are arising as cleaner options for sustainable production in modern industry, with adhesive-bonded joints increasingly being used as design solutions in complex products and assemblies. However, the use of structural adhesives has several significant drawbacks, most of which are related to environmental impact, linked to the nature of the adhesive substance, as well as product disassembly/disposal deriving from the fact that adhesive joints are usually irreversible. Within this context, the goal of this paper is to study adhesive joints in mechanical assemblies from a life cycle perspective, offering more comprehensive analysis tools and assembly solutions suitable for industries such as automotive, aerospace, and assembly/packaging machinery. A methodological framework for the comprehensive characterization of bonded joints using effective surface activation techniques has been created and tested. The first phase encompasses the production of samples for mechanical testing under static and fatigue loading conditions. The second includes the characterization of inputs/outputs (life cycle inventory—LCI) for life cycle assessment (LCA) of mechanical assemblies employing adhesive joints and innovative surface activation techniques. The final phase provides a set of eco-design actions based on a critical analysis of the obtained results. The outcomes demonstrate how it is possible to achieve optimal adhesive-bonded joint properties under specific working conditions (e.g., static or fatigue loading) while maintaining a low environmental load using novel surface pre-treatments such as laser and plasma technologies. These outcomes are supported by a case-study in which adhesive joints are applied to the mechanical assembly of a bottle gripper for a food packaging machine. The adoption of eco-design rules in adhesive joint applications will help designers in the development of suitable solutions for lightweight applications from a complete life cycle perspective.

Keywords: Adhesive bonds , Environmental impact , Fatigue , Laser texturing , LCA , Surface activation

In the era of Industry 4.0, designers are expected to use new tools and approaches to innovate the design of products and services. From this perspective, the integration of design practices and technologies of the 4.0 transition can have positive implications for sustainability. Several current issues can be addressed and among them, honeybee death is relevant. Honeybees are fundamental to the ecosystem and human life. Nevertheless, their lives are extremely at risk due to exposure to several disease factors. After conducting expert interviews, the paper presents a conceptual model of intelligent beekeeping to monitor the health status of honeybees. Furthermore, after user research, the paper proposes a co-design model for urban beekeeping, scaled up to a condominium dimension, to allow condominiums and expert beekeepers to be part of an integrated design model. The critical proposition of this model is to raise awareness of the problem of honeybee death to achieve 3 out of 17 United Nations' Sustainable Development Goals: Good Health and Well-Being, Sustainable Cities and Community, and Life on Land. Early results report positive values of acceptance of the urban beekeeping practice by users and the use of IoT in managing beehives and their health status by expert beekeepers.

Keywords: Co-design , Design for sustainability , Industrial design , Industry 4.0 , IoT technology , Urban beekeeping

Purpose: This study evaluates the potential of using the material extrusion (MEX) process for recycling waste tire rubber (WTR). By investigating the process parameters, mechanical behaviour and morphological characterisation of a thermoplastic polyurethane-waste tire rubber composite filament (TPU-WTR), this study aims to establish a framework for end-of-life tire (ELT) recycling using the MEX technology. Design/methodology/approach: The research assesses the impact of various process parameters on the mechanical properties of the TPU-WTR filament. Hysteresis analysis and Poisson's ratio estimation are conducted to investigate the material's behaviour. In addition, the compressive performance of diverse TPU-WTR triply periodic minimal surface lattices is explored to test the filament suitability for printing intricate structures. Findings: Results demonstrate the potential of the TPU-WTR filament in developing sustainable structures. The MEX process can, therefore, contribute to the recycling of WTR. Mechanical testing has provided insights into the influence of process parameters on the material behaviour, while investigating various lattice structures has challenged the material's capabilities in printing complex topologies. Social implications: This research holds significant social implications addressing the growing environmental sustainability and waste management concerns. Developing 3D-printed sustainable structures using recycled materials reduces resource consumption and promotes responsible production practices for a more environmentally conscious society. Originality/value: This study contributes to the field by showcasing the use of MEX technology for ELT recycling, particularly focusing on the TPU-WTR filament, presenting a novel approach to sustainable consumption and production aligned with the United Nations Sustainable Development Goal 12.

Keywords: Additive manufacturing , Circular economy , Design for additive manufacturing , Recycling , Sustainability , Sustainable Development Goals , Triply periodic minimal surface , Waste tire rubber

Eco-design has increasingly become a necessity to safeguard the eco-system. However, eco-assessment methodologies, e.g. the Life Cycle Assessment (LCA), fail to rigorously and reliably support the evaluation of future products, as well as emerging technologies, ideas and concepts in eco-design. This study lays some theoretical foundations for the development of a step-divided systematic method to support Prospective LCA based on a structured patent analysis. In order to answer the prescribed requirements, for each of them, some specific strategies of patents analysis have been collected and systematically organized. The aim of the proposed method is to compare technologies with a different level of maturity, contrary to the traditional LCA which overestimates the existing ones only because are more optimized. The proposed method was applied to a real case study about the production of titanium powder to perform the prospective LCA of the patented future developments of the components of this process. The results showed that, patent analysis, systematized through the proposed method, can be used to forecast the environmental impact of a future product. The scale-up of the performances can be esteemed, by ensuring at the same time the comparability and the reliability and the results, as prescribed by reference standards.

Keywords: eco-design , patent analysis , product forecasting , Prospective LCA

Healthcare sector has a significant impact on the environment. While telemedicine techniques could be a solution to increase its sustainability, the methods for a quantitative evaluation are poorly applied and often generate a partial assessment. Therefore, the main aim of the present research is the definition of a methodology for a preliminary quantification of the environmental impact generated by the process to perform a televisit. The methodology has been structured in 4 phases: process identification, impacts detection, data elaboration and results analysis. A real case study was performed including follow-up televisits for cardiopathic patients. After having defined the setting of the study, a list of tasks was prepared. For each task physical wastes, devices energy consumption, telecommunications and transportation were investigated. Equivalent CO2 (CO2 eq) was calculated involving sources from studies in literature and official websites. Although televisit reduces the impacts caused by patient travel, the use of telecommunications during supporting activities caused a significant amount of CO2 eq. Therefore, a complete assessment has to include the entire process of televisit. Despite the average input data, the methodology offers a base that could be improved with other impact indicators.

Keywords: Assessment Tool , Environmental Sustainability , Process Modeling , Sustainable Development , Telemedicine

The increasing significance of batteries in the 21st century and the challenges posed by the anticipated surge in end-of-life batteries, particularly within the European context, are examined in this study. Forecasts predict a notable escalation in battery waste, necessitating a focus on the recycling of black mass (BM)—a complex and hazardous byproduct of the battery recycling process. Employing systematic analysis, this research investigates the hazardous nature of BM derived from various battery types. The study underscores the urgent need for definitive legislative classification of BM's hazardous properties (HPs), in accordance with European regulations. This comprehensive examination of BM's HPs contributes significantly to the understanding of BM recycling complexities, proving essential for industry stakeholders and guiding future developments in this field. Additionally, the study explores innovative technologies and strategies that could improve recycling efficiency and reduce associated risks. A pivotal finding of this investigation is the inherently hazardous nature of BM, leading to the recommendation that BM should be classified at a minimum under the “HP3—Flammable” category. This discovery underscores the critical need for stringent management protocols and robust regulatory frameworks to address the burgeoning challenge of battery waste in Europe.

Keywords: battery recycling , battery waste , black mass , European Regulations , hazardous properties , recycling technologies , waste classification , waste management

Submerged lifting surfaces technology, born in the early 1900s, allows boats to lift the hull above the water and, in some cases, halves the resistance compared to dislocated and planning boats. This paper illustrates the state-of-the-art on hydrofoil technology, highlighting the fundamental aspects of the study of submerged wings and focusing on the problems that this technology presents, evaluating the solutions currently used to optimize its work. Key aspects of hydrofoil design are addressed, such as the choice of geometric configurations and two-dimensional profiles suitable for each type of mission. This results in addressing issues associated with cavitation and ventilation and emphasizing structural solutions that reduce these phenomena, thus improving hydrofoil efficiency. The study analyses and discusses the problems of wing systems used in existing applications, with the aim of developing a sustainable transport technology compatible with ecological propulsions such as hydrogen and electric.

Keywords: green , hydrodynamics , hydrofoil , sustainable

The issue of eco-friendliness and sustainable development is crucial in various domains of our lives. This also affects the production of products and the provision of services. One of the first stages of a product's life deserves special attention, i.e. the area of new product development, in which all its features and limitations are defined, which also results in the type of manufacturing process. Therefore, this paper aims to explore and propose the possibility of implementing mechanisms for evaluating the environmental performance of products and processes at that stage of product life using product life cycle management tools. One of the main assumptions was that the developed data model would facilitate sharing of experiences and knowledge with an open community of users. For this purpose, the concept of effective community knowledge management in new product development was developed. The proposed model of such a framework considers the significant participation of all actors and data sources, both internal and external, in creating and managing the knowledge base about green indicators and related objects. In the final step, we present the concept of effective management and sharing of knowledge by the community, creating the Green Product Lifecycle Management user community cloud to ensure the collected data's highest quality (ranking) and quantity (gamification). The work described was conducted and implemented in the GreenPLM project, which aimed to extend the functionality of existing systems to enable the assessment of the environmental performance of new products and processes at various stages of their lives.

Keywords: Community , Knowledge Management , New Product Development , Product lifecycle management , Sustainability

In the context of Industry 4.0, industrial robots are experiencing wider application fields due to improved capability of executing flexible and diversified manufacturing cycles. The implementation of mechatronic automation systems remains a critical task, since it must cope with many heterogeneous domains, from layout definition to design of mechanical, actuating, and sensing devices, control logic coding, testing and optimization of the whole system. This paper leverages a Python-based connection between a simulation software for robotic cells, i.e. RoboDK, and a PLC system, i.e. Beckhoff TwinCAT, to realize a holistic virtual prototyping environment able to support the design and virtual commissioning of automation systems. The proposed approach is demonstrated with a case study comprising a robotic deburring cell. The resulting application shows the ability to effectively debug logic code, optimize the sequence of manufacturing tasks, and monitor the primary kinematic quantities.

Keywords: RoboDK , Robotic cell , TwinCAT , Virtual Commissioning , Virtual prototyping

Sustainability-oriented new product development process is becoming of key importance in many sectors of the industry. Especially in the automotive industry, it plays a major role as this sector is historically associated with resource-intensive production and fossil fuel consumption, and thus has to implement solutions that will contribute to restraint of climate change. Manufacturing companies are currently faced with the challenge of adapting their business models to changing market expectations and requirements resulting from the sustainable development path. Moreover, the development of the new digital factories and pressure from the legislators require adjustment of existing Product Lifecycle Management systems. To enhance the concept of the Green Product Lifecycle Management which is still under development, in this work we propose a new three-step methodology composed of three main steps: (1) assessing indicators' importance for sustainable business goals and business models, (2) assessing indicators and their importance in the automotive industry, (3) assessing “greenness” of the product. This complex approach is innovative as it is based on the business-oriented perspective. Selecting suitable business goals and corresponding business models leads to the selection of the appropriate subset of green indicators. Several more aspects are taken into account in this holistic analysis: the indicator's features, relevance for the company, importance to sustainable business goals, importance in terms of subsectors of the automotive industry as well as environmental, economic, and social impact. This approach enables the company to compute the value of the greenness of the product in reference to the key green indicators.

Keywords: Automotive industry , Business goals , Circular economy , Digital manufacturing , Product lifecycle management , Sustainability

Addressing sustainability challenges requires shifts in consumption patterns and lifestyles. Design for Sustainable Behavior (DfSB) aims to cultivate sustainable attitudes and behaviors through product-based interventions. However, there can be a disconnect between design strategy and its embodiment and sometimes conflicts between designers' intent and users' interpretation. This paper explores the role of metaphors in DfSB in terms of using metaphorical thinking during the design process and/or creating product metaphors in the final design. It begins by identifying barriers that prevent people from engaging in sustainable practices, such as human nature and ambiguity in design. It then examines the roles of metaphor in design and its key strengths in DfSB. Furthermore, the paper outlines three methods to generate metaphors in DfSB: (1) The source domain implies the target domain. (2) The source domain serves design goals and strategies. (3) Cross-domain mapping is based on embodied experience. In conclusion, the paper discusses potential issues surrounding its use in DfSB.

Keywords: Behavior change , Design for sustainable behavior , Metaphor , Metaphorical thinking , Product design , Sustainability communication