Time to read: 8 min
We want the products we design to last — to perform reliably, win market adoption, and deliver long-term value. But it’s not ideal if they last forever in a landfill, or negatively impact the planet we depend on.
That balance is at the heart of sustainable product design. As environmental awareness grows and regulations become more stringent, Design for Sustainability (DFS) principles are becoming essential. Manufacturers are recognizing that by integrating sustainability into design from the start, they can reduce environmental impact, improve efficiency, and strengthen long-term competitiveness.
Let’s get into the key principles and applications of DFS, sustainable materials that help make it a reality, and how to overcome challenges during analysis and implementation.
What Is Design for Sustainability?
Design for Sustainability (DFS) is an engineering approach that focuses on designing products to minimize environmental impact throughout their lifecycle. It involves choosing sustainable materials, optimizing manufacturing processes, and designing for reuse, recyclability, and energy efficiency. DFS helps companies reduce their carbon footprint and meet regulatory requirements.
The sustainable design philosophy aims to minimize adverse impacts on people, animals, the environment, and the economy. It can be integrated into and balanced with the traditional design approach, which is typically more narrowly focused on product cost, functionality, and aesthetics. DFS fits within the broader framework of Design for Excellence (DFX), working alongside methodologies such as Design for Manufacturing (DFM), Design for Assembly (DFA), and others.
Key Principles of Sustainable Design
Fundamental principles of sustainable design include:
- Reduce: Reduce the use of single-use and toxic materials.
- Reuse: Design products that are durable and reusable.
- Recycle: At the end of life, the product can be broken down into raw materials and reused. It is key that the process uses less energy than creating new raw material.
- Optimize: Optimizing for the most efficient process, which reduces waste and energy usage.
However, sustainable design extends far beyond that. It includes reducing water consumption, lowering energy use, adopting carbon-free energy sources, and improving air quality. Some of these objectives can be achieved by studying nature and applying Biomimicry principles. For example, nature harnesses sunlight as its primary energy source and relies on local resources.
Technology has also drawn inspiration from nature. Velcro, for instance, was developed by copying the mechanism seeds use to cling to animal hair. Technologies can further work in harmony; for example, data centers are partnering with leisure facilities to heat swimming pools while simultaneously cooling servers, saving costs and reducing energy consumption.
Sustainable product lifecycle
Lifecycle Assessment (LCA) and Its Role in Sustainable Design
Lifecycle assessment (or analysis) looks at the costs and benefits of a product from “cradle to grave”—from raw material extraction/creation to end-of-life management. This approach enables designers to identify opportunities to minimize environmental impacts, conserve resources, and lower costs. ISO 14040 is the international standard that provides guidance on what qualifies as a life cycle analysis and how to conduct one. There is a standard task checklist for engineers to undertake, which includes:
- Goal and Scope: The goal and scope step is used to define what the LCA will and will not examine. When analysing a product life cycle, not everything can be taken into account. If there is reasonable evidence to suggest that certain aspects aren’t high impact, then they can be removed from the analysis.
- Inventory: An inventory of all the information used for the analysis is required. Information can include emissions, energy consumption, and end-of-life considerations.
- Impact Assessment: Using the inventory, an impact assessment is carried out against key factors such as ozone depletion, acidification of the local ecosystem, human toxicity potential, etc.
- Interpretation and Improvement Assessment: Interpretation makes sense of the LCA data and evaluates the study’s reliability and integrity, and not all impacts can be measured perfectly. The improvement assessment compares the impact assessment against the goal and scope to determine if the goals have been achieved within the defined scope. Recommendations for improvement can be added to this section.
Sustainable Materials and Processes
Material selection makes a big difference when it comes to achieving design for sustainability goals. Here are some examples:
Sustainable Metals
Opting for renewable materials is a key aspect of meeting sustainability objectives. In terms of metals, this can include both aluminum and steel, which are both recyclable. Approximately 75% of all aluminium extracted is still in use today, according to the International Aluminum Institute. However, aluminum alloys are more difficult to recycle back to raw aluminum, which is a potential issue in industries such as aerospace, where control over metal impurities is crucial to safety.
Sustainable Plastics
Opting for sustainable plastics can also improve cradle-to-grave design. Plastic recyclability can depend on its type; generally, thermosets are more challenging to recycle than thermoplastics, as they have undergone irreversible molecular bonding. This could mean using recyclable plastics such as high-density polyethylene (HDPE), Polyethylene terephthalate (PET), or Polypropylene (PP).
Some non-recyclable plastics can be substituted for bio-based plastics, which are sourced from renewable plant matter. Although many bioplastics are compostable, not all are, so bioplastic use isn’t necessarily better. This can also be due to the fact that sourcing them is more energy-intensive. Some bioplastics, like PLA, can only be composted in industrial facilities.
Sustainable Packaging
Sustainable packaging design is an important part of reducing a product’s overall environmental impact. By minimizing the amount of material used, prioritizing recyclable options such as corrugated cardboard or molded pulp, and avoiding excessive plastics, manufacturers can significantly cut waste. Right-sizing packaging to fit the product not only reduces material consumption but also improves logistics efficiency by lowering shipping weight and volume, which in turn reduces transportation emissions.
Sustainable Processes
Different processes can be used to increase sustainability, such as using slag concrete, which incorporates a byproduct of steel production known as ground granulated blast-furnace slag (GGBFS) to replace part of the Portland cement in concrete, which reduces carbon emissions.
DFS Applied to Common Manufacturing Processes
Sustainability in Injection Molding
Design of injection-molded products can use DFS and DFM principles to reduce energy consumption by using low-temperature plastics and more efficient heaters. This would also be a Design for Manufacture principle as the production process is optimized. Injection molding can increase the sustainability of its products by using bioplastics, which are sustainably sourced and can be biodegradable, or by using recycled plastics. However, bioplastics are not always an option due to their lower performance. Choosing the right material is critical for sustainability.
Sustainability in CNC machining
CNC machining processes can use raw materials that closely match the final part to reduce the amount of material cut and the energy used for cutting. One way companies are doing this is by using additive manufacturing to make the stock material and then using CNC machining to create a part with high tolerances and surface finish. Waste metal can also be recycled to further reduce material consumption. Additionally, CNC machining can use water-based or vegetable oil-based coolant, as opposed to mineral-based coolants, to reduce the toxicity of the coolant. Here are some other tips for sustainable CNC machining.
Sustainability in Sheet Metal
Sheet metal fabrication can be optimized for sustainability by using nesting techniques, in which cuts of material are nested together to minimize the waste of material. If any waste is produced, then it is important that recyclable metals are recycled. Similarly to machining, waste metal and even final products can often be recycled.
Sustainability in 3D printing
3D printing (additive manufacturing) supports DFS principles by its very nature, as it minimizes the kind of waste produced in traditional subtractive CNC machining methods. Subtractive processes have to start with a block of material from which waste is guaranteed to be created, no matter how carefully the designer selects the raw material shape and size. 3D printed products can be printed geographically closer to the place of sale, reducing long supply chains and energy required to ship parts. However, for higher volumes, other manufacturing processes may have a lower carbon footprint.
Common Pitfalls to Avoid in Sustainable Design
- Buzzwords: Materials may be labeled with terms like “green plastics,” but it’s important to be diligent and ensure the material or process provides a net improvement over traditional options.
- Alloys: While alloys are necessary in some designs, they can be problematic since the distinct materials are difficult to separate at the end of life, making recycling more challenging.
- Greenwashing: This occurs when goods and services are marketed as sustainable but still cause environmental harm. For example, some bioplastics may be compostable, but if their production requires deforestation, they are not truly sustainable.
Design for Serviceability: Extending Product Lifespans
An important aspect of sustainable design is Design for Serviceability (DFSv), which ensures that products can be repaired, upgraded, and maintained instead of being thrown away when something goes wrong. By making products easier to service, manufacturers can extend their useful life, reduce waste, and lower the environmental impact of replacement cycles.
Key principles of serviceability include:
- Modular components: Products designed with interchangeable parts allow worn or damaged elements to be replaced without discarding the entire product.
- Accessible assembly: Using standardized fasteners rather than adhesives makes disassembly straightforward and reduces the need for specialized tools.
- Repair support: Providing documentation, diagnostic tools, and spare parts helps both users and service providers carry out repairs safely and effectively.
- Upgradability: Allowing for hardware swaps or software updates ensures products can adapt to new requirements and stay relevant longer.
Designing for serviceability recognizes that components will eventually fail—but with thoughtful engineering, failure does not need to result in waste. A phone with a replaceable battery or an appliance with a replaceable motor can remain in service for many more years, supporting both customer value and sustainability goals.
Trade-Offs: Balancing Sustainability, Cost, and Reliability
Out of the trade-offs when choosing renewable materials and methods for manufacturing, one of the main concerns is cost. Renewable materials are often more expensive due to smaller economies of scale and the specialist skills required to produce them, which are a result of low historical demand.
There is also a balance to be made between designing for reliability and recyclability, as increased durability often means reduced recyclability. While many materials are durable, they may also be non-recyclable and end up being burned or in landfills. A balance can often be made by using natural materials such as natural fiber for bags and clothing, which is both durable and sustainable.
These trade-offs are not easy to identify and require calculating every impact made by the design process and comparing them. This is why it is best to use a life cycle analysis software to compare the quantitative data.
Tools and Resources for Engineers
The lifecycle analysis to help assess a product’s sustainability can be conducted using lifecycle analysis software such as SimaPro, Sphera (GaBi), or openLCA. These programs allow the user to measure the sustainability impact of all design choices from conception to the end of life. These measurements can be compared and contrasted with different design choices to work out the most sustainable method of design by using calculations created by leading LCA experts.
Suppliers’ sustainability can be evaluated using specialized supplier sustainability scorecards, which assess the environmental, social, and governance (ESG) impacts of suppliers. Scorecards found in the LCA analysis software provide a framework for measuring and comparing suppliers’ sustainability efforts.
To gain insights into sustainability in industry, read Fictiv’s 2023 sustainability report.
Driving Sustainability Through Smarter Design
DFS helps to reduce the harmful impact of products on the environment and the human community. Both customer and regulatory requirements for sustainable manufacturing practices are increasing. Sustainability requirements can be met with design thinking, sustainable materials and processes, and life cycle analysis tools to measure sustainability impacts. Bring your sustainable designs to market with speed and confidence using Fictiv’s digital tools and expert manufacturing network. Start your custom manufacturing quote today.
