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Product design is one of the most important sectors influencing global sustainability, as almost all the products consumed by people are outputs of the product development process. In particular, early design decisions can have a very significant impact on sustainability. These decisions not only relate to material and manufacturing choices but have a far-reaching effect on the product's entire life cycle, including transportation, distribution, and end-of-life logistics. However, key challenges have to be overcome to enable eco-design methods to be applicable in early design stages. Lack of information models, semantic interoperability, methods to influence eco-design thinking in early stages, measurement science and uncertainty models in eco-decisions, and ability to balance business decisions and eco-design methodology are serious impediments to realizing sustainable products and services. Therefore, integrating downstream life cycle data into eco-design tools is essential to achieving true sustainable product development. Our review gives an overview of related research and positions early eco-design tools and decision support as a key strategy for the future. By merging sustainable thinking into traditional design methods, this review provides a framework for ongoing research, as well as encourages research collaborations among the various communities interested in sustainable product realization. [DOI: 10.1115/1.4002308] Keywords: sustainable design, eco-design, product design, manufacturing, supply chain

Understanding the limits of a design is an important aspect of the design process. When mathematical models are constructed to describe a design concept, the limits are typically expressed as constraints involving the variables of that concept. The set of values for the design variables that do not violate constraints constitute the design space of that concept. In this work, we transform a parametric design problem into a geometry problem thereby enabling computational geometry algorithms to support design exploration. A polytope-based representation is presented to geometrically approximate the design space. The design space is represented as a finite set of (at most) three-dimensional (possibly nonconvex) polytopes, i.e., points, intervals, polygons, and polyhedra. The algorithm for constructing the design space is developed by interpreting constraint-consistency algorithms as computational-geometric operations and consequently extending (3,2)-consistency algorithm for polytope representations. A simple example of a fingernail clipper design is used to illustrate the approach. [DOI: 10.1115/1.4001528]

The issue of environmental sustainability, which is unprecedented in both magnitude and complexity, presents one of the biggest challenges faced by modern society. Design engineers can make significant contributions by incorporating environmental awareness into product and process development. It is critical that engineers make a paradigm shift in product design from centering on cost and performance to balancing economic, environmental, and societal considerations. Although there have been quite a few designs for environment (or ecodesign) tools developed, so far, these tools have only achieved limited industrial penetration. The present-day methods are either too qualitative to offer concrete solutions and not effective for designers with limited experience or too quantitative, costly, and time consuming. Thus, current ecodesign tools cannot be implemented during the early design phases. This paper develops a novel, semiquantitative ecodesign methodology that is targeted specifically toward the early stages of the design process. The new methodology is a combination of environmental life cycle assessment and visual tools such as quality function deployment, functional-component matrix, and Pugh chart. Since the early design process is function-oriented, a new visual tool called the function impact matrix has been developed to correlate environmental impacts with product function. Redesign of office staplers for reduced carbon footprint has been selected as a case study to demonstrate the use of the proposed approach. Life cycle assessment results confirm that the new stapler design generated using this methodology promotes improved environmental performance. [DOI: 10.1115/1.4001890] Keywords: ecodesign, visual tool, life cycle assessment, function impact matrix