To enable a circular economy, remanufacturing is considered a key strategy due to the high level of value retention. However, for short-cycled products, the accelerated obsolescence of conventionally remanufactured products on the secondary market poses challenges to leverage the potential. Cross-Generational Remanufacturing (CG-Reman) has been developed as a new concept in response, which aims to restore used products into the latest generation for sale on the primary market. For its practical success, it is critical to support product engineers in designing products suitably. Hence, in this paper we further explore the overall CG-Reman process with a lifecycle description, derive requirements for the product’s design and conduct a systematic literature review of 209 sources targeting selection, clustering and matching of Design-for-X (DfX) guidelines with the needs for CG-Reman.

Laser Powder Bed Fusion (LPBF) enables complex metal components for the space industry. However, as-built surface roughness affects material properties and is closely linked to design geometry. As computer-aided design tools struggle to model roughness accurately, this study explores Additive Manufacturing Design Artefacts (AMDAs) to investigate design-related roughness and its impact on fatigue performance. A space industry case study using AMDAs to replicate a 4 mm unsupported roof radius of a rocket engine component found fatigue performance reductions of 88% in horizontal builds and 65% in vertical builds compared to machined surfaces. Microstructural analysis confirmed the influence of roughness and grain structure on fatigue behaviour. Findings highlight how AMDAs provide design-specific insights and support engineers in investigating uncertainties.

This paper demonstrates how the Portfolio of Capability Constraint Network (PCCN) facilitates modeling and analyzing complex manufacturing networks by framing them as constraint satisfaction problems (CSPs). These models face high complexity due to numerous n-ary constraints and large solution spaces, posing challenges for standard solution algorithms. Existing CSP remodeling approaches were reviewed but found unsuitable for the specific needs of PCCNs. As a result, tailored design guidelines and heuristics were developed to reduce problem complexity effectively. The applicability of these guidelines was validated using a use case involving the production of a multi-material shaft with tailored forming technology. Results showed significant efficiency gains in solution searches, emphasizing the practical value of the proposed methods in simplifying and optimizing PCCN-based models.

The circular economy has long been regarded as a fundamental strategy for achieving sustainable development. Most recently, it has also been acknowledged as an effective approach to crisis response. This study contributes to this nascent literature by introducing a dual hierarchy of 6Rs strategies as an inspiring framework for circular post-disaster recovery and reconstruction, supporting the “Build Back Better” principle through circular initiatives. The key distinction between the proposed hierarchy and the traditional 6Rs framework lies in the two-vector operationalization of each strategy, addressing both past and future considerations. Also, this article examines the case of war-torn Ukraine as one of the most severe man-made disasters. The study explores Ukraine’s potential for circular recovery within the framework of European Union policies in the construction sector.

The transition to renewable energy and the urgent need to reduce greenhouse gas emissions highlight green hydrogen’s role in decarbonizing various sectors. To address the increasing demand, the research initiative H2Giga FertiRob focuses on automating the production of hydrogen electrolyzers, emphasizing PEM stack assembly. Existing stack designs are often incompatible with automation and hinder scalable production. This paper introduces an adapted Design for Automation approach for PEM stacks. Through the evaluation of a reference stack, key design limitations are identified, leading to the development of an optimized stack with reduced part diversity, improved handling, and enhanced automation compatibility. The methodology provides a systematic framework to advance the automated production of PEM stacks, supporting the scalability of green hydrogen in the global energy transition.

Digital products and applications are rapidly evolving, offering immense potential to drive social change and encourage sustainable behaviors. This raises a critical question: how can we effectively design these products to support and inspire sustainable practices? This paper presents a literature review of design for sustainable behavior (DfSB) strategies across various digital and physical product-service systems in engineering design and human-computer interaction. The review examines DfSB intervention trends over the last decade, highlighting the increasing diversity of technological interventions, and categorizes the design methods employed in these technologies. These categories identify opportunities where future DfSB interventions can be applied and illustrate how the unique affordances of digital vs physical technologies can be effectively used to support sustainable practices.

The importance of the circular economy as an alternative to today’s prevailing linear economy is recognised in both industry and research. Product designers are having a major influence on this transition by adapting the characteristics of physical products in the early phases of the product development process. However, most products follow a linear approach and are far from being circular. This paper aims to identify the challenges that product designers face when designing circular products. Building on a developed understanding of related terms in circular product design, an exploratory literature review is conducted. The results help to gain an overview and understanding of the challenges that need to be addressed. Therefore, further research directions are derived to support the transition from linear to circular products in the long term.

This work is driven by the aim to minimize material waste in the production of structural sheet metal components. Thus, a rule-based decomposition process for multiply connected planar shapes is presented, analyzing the shape’s boundary and skeleton. Based on four cutting rules, shapes are decomposed to particularly extract straight and strut-like parts, allowing high packing densities for a reduction of material waste. Additionally, an alternative shape decomposition scenario is described, aiming for the avoidance of stress hotspots in structural components. In a case study with various shapes, effects on material waste are investigated involving a strip packing problem. Furthermore, effects on mechanical stress are analyzed. The results show potential to reduce material waste, but also disadvantages regarding mechanical stress. Aspects for further consideration are pointed out.

Product development is critical for sustainable development, yet sustainable design practices remain under-implemented in the industry. This paper explores the aerospace sector, addressing its specific barriers and enablers to sustainable design. Through a comprehensive literature review, group discussions, and expert group interviews, this study introduces an impact model with essential elements for enabling sustainable product development in aerospace and explains their causal relations. Five key elements were identified: business drive, sustainability implementation, knowledge, ownership, and collaboration. In addition to the impact model, the paper discusses aerospace-specific challenges and opportunities for sustainable product development. Findings from this study offer a practical framework for practitioners and researchers to plan and implement interventions in organizations.

Current legislative frameworks reflect a societal consensus to prioritize sustainability, incentivizing industries to integrate environmental goals into strategic objectives. Embedding sustainability into product development requires appropriate methods and tools. Technological advancements enable the utilization and analysis of operational machine data to support the development of new generations of sustainable systems and the conduction of Life-Cycle-Assessments. This research presents a method to support data-driven product development to reduce the environmental impact of new product generations of complex mechatronic systems during operation, addressing key factors such as the technical system, organizational infrastructure, and regulations. The application of the method resulted in multiple proposed design changes able to enhance machine sustainability and operational efficiency.

The rapid increase in Waste Electrical and Electronic Equipment (WEEE) presents significant environmental challenges, requiring the development of efficient and effective disassembly and recycling strategies. Although extensive theoretical research has explored product redesign to facilitate automated disassembly, practical validations of such approaches remain limited. This study examines the technical feasibility of applying design-for-disassembly principles to enable automated dismantling processes using general-purpose robotic systems. Using a consumer electronic remote control as a case study, this paper demonstrates how targeted product redesign can improve compatibility with robotic systems during disassembly. The findings provide valuable insights into sustainable product design and end-of-life management, with implications for supporting a circular economy.

Products are often optimized for “most likely” conditions, but unexpected variations can render designs ineffective. Using examples from engineering systems, this paper explores the benefits of leveraging non-linear “payoff functions,” where small changes in conditions lead to disproportionate outcomes. By analyzing the direction and curvature of these functions near observed boundaries, designers could gain an understanding of behavior beyond expected ranges. Non-linear modeling can aid in assessing design margins, especially in long-lived systems. Integrating this approach into design processes can be helpful and effective in considering the “preparedness” of a system in the face of unexpected events of different natures.

Current quantitative methods for estimating product-related environmental emissions face limitations in supporting sustainable design, particularly in second-life product strategies. This paper highlights challenges in accurately assessing emissions and environmental impacts under existing regulations, which often fail to reward designs enabling circularity. Through examples of current practices, it underscores methodological ambiguities and regulatory gaps, proposing a research agenda for improved tools and frameworks. These advancements aim to better support the design, production, and certification of sustainable, second-life-ready solutions, fostering more effective environmental impact reduction. Additionally, the paper emphasizes the need for regulatory adaptation to incentivize circular design practices, ensuring a fair evaluation of products conceived for second-life applications

Generative Design (GD) tools can produce high-performing components with complex geometries that are challenging to conceive via traditional methods. While potentially disruptive, GD tools have yet to achieve widespread use in industry. One reason is that current GD tools are limited to manufacturing methods capable of producing intricate geometries that GD often creates such as 3D printing. To overcome this barrier, this paper quantifies the benefit of altering generatively designed parts to use standardized elements like wire stock and sheet metal via processes such as CNC bending and water jet cutting. Using a parametric cost model, we show that parts incorporating standard components can halve the unit price for production volumes of only 4 parts. Finite Element Analysis (FEA) reveals that replacing up to 60% of part volume has minimal impact on performance. Our findings highlight a gap and opportunity in existing GD research.

This paper presents a motion-based taxonomy for classifying lattice structures in additive manufacturing (AM) based on their geometric suitability for linear, oscillating, reciprocating, and rotary motions. While existing classification frameworks primarily focus on static load-bearing performance, this study develops a geometry-driven taxonomy, classifying 51 lattice variations based on how tessellation patterns and wall thickness influence motion-driven deformation. The taxonomy provides a framework independent of materials, aiding the selection of lattices for compliant structures, and energy-absorbing applications, by isolating geometric tessellations to assess their role in dynamic deformation and motion suitability. This approach links lattice geometry to motion-driven behaviour, offering a predictive framework for AM design while emphasising its role in motion applications.

The manufacturing process selection (MPS) greatly influences possible design decisions regarding the product’s embodiment. However, a gap remains in understanding how design engineers make these selections and what data and resources inform them. Through semi-structured interviews with engineers across various mechanical engineering industries insights into current decision-making processes are gained. The findings reveal that MPS is mostly guided by personal and collective experience, with influencing factors such as functionality and product quantities. The use of support tools remains limited. A systematic integration of data-driven tools and structured knowledge management is mostly absent. It’s concluded that reliance on experiential knowledge risks overlooking alternative processes and integrating systematic tools with existing experience-based practices could enhance MPS.

From an economic perspective, the appeal of a product diminishes over time. However, volatile markets and divergent technological advancements make it challenging to anticipate when and to what extent changes will be necessary. Therefore, it is important to be able to integrate changes after a product's launch. This paper provides an overview of different perspectives on the product lifecycle. In addition, the paper presents an empirical study on implementing changes at an automobile manufacturer.

The spare parts play a vital role in sustaining the operation and longevity of products and systems, but their unavailability can lead to prolonged downtime or expensive replacements. The integration of 3D scanning and Additive Manufacturing (AM) presents a promising path for spare part production. However, to utilise the full potential of AM, sometimes, redesign of the original part is needed. This paper investigates and proposes a new approach that integrates reverse engineering and redesign of an original part based on functional analysis to support the manufacturing of AM spare parts.

In today's competitive market, design firms are under pressure to enhance the speed of their decision-making processes to foster innovative products. Due to specialized nature of contemporary technology, enterprises are directed to consider Design for X factors during the product development process like environmental impact and production efficiency. This transformation leads to an increase in gaining knowledge from different fields. This paper presents a comprehensive framework for efficiently acquiring and applying knowledge, aimed at improving knowledge management and sharing practices.

This study envisions a unified paradigm for design for automated disassembly. The goal is to integrate disassembly insights related to precious material recovery with the design phase for sustainable lifecycle management.Targeting plastic products with embedded electronics, the collaboration between design and robotic engineers aims to program a robot for disassembly for the LEGO® motor (45603) as demonstration, emphasizing a disassembly map as a vital tool. By considering the limitations and strengths of robots, this research pioneers a design for disassembly framework.