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Diversifying energy sources and managing waste biomass are two pressing contemporary issues. The new technology proposed in this study aims to address both by converting waste biomass into energy and fertilizer through the use of a biofuel cell (BFC). The purpose of this study is to assess the environmental impacts associated with this innovative technology through a Life Cycle Assessment (LCA). To achieve the goal, the production and use of the cell were modelled, considering both laboratory-scale operations and industrial-scale approximations. The study explored alternative scenarios, such as sensitivity analyses involving different acids and bases, renewable energy sources, and heat recovery. Comparisons with conventional biomass waste treatments (anaerobic digestion and composting) demonstrated that the BFC technology remains competitive. To further improve the BFC’s environmental footprint, efforts should focus on reducing energy requirements and enhancing nutrient recovery during scale-up. These insights are crucial for advancing sustainable waste treatment technologies and maximizing the potential of discarded biomass in an environmentally friendly manner.

At the end of its life the packaging may become a residue if it is not correctly discarded, becoming a visible component of the waste produced on the planet, with a defined shape and communicating with the world. In the same way, large-scale agricultural production generates organic residues that, although representing fiber-rich materials, are discarded, such as rice husk, coconut husk, wood fibers, among others. To contribute with solutions to minimize the environmental impact of packaging and organic residues, the present study aims at performing preliminary tests of molded pulp packaging manufacturing from organic residues, in a circular economy context. Action research was used as the method to guide the collective construction (project team and partner companies), and the direction of the preliminary tests of packaging to be manufactured. The tests performed on coconut fibers in transfer molding and thermoforming were promising, but they required the addition of binder substances like byproducts from starch, especially in the transfer molding method. Besides using fibers from alternative sources to cellulose, the proposed packaging is potentially compostable and may replace non-renewable material like oil-based polymers.

Circular design represents a key pillar in the transition towards a sustainable economy. This article examines the current state of research and application of circular design in key industries such as textiles, packaging, electronics, and construction. The main methodologies used—Life Cycle Assessment (LCA), ecodesign, biomimicry, and the analysis of renewable materials—are discussed alongside concrete examples and relevant European initiatives. Current challenges and innovation opportunities are highlighted, emphasizing the role of design as a strategic tool for waste reduction, increased product durability, and achieving climate neutrality.

Considering a growing number of metrics and indicators to assess circular economy, it is of paramount importance to shed light on how they differ from traditional approaches, such as life cycle assessment (LCA) or sustainability performance indicators. This study provides new empirical insights on the correlation between LCA, circularity, and sustainability indicator-based approaches. Specifically, the importance lies in analyzing how the results generated by these different approaches can be used to support the design of products that are not only circular, but also sustainable. A practice-based project involving 87 engineering students (divided into 20 groups) is conducted with the aim to compare and improve the circularity and sustainability performance of three product alternatives of lawn mowers (gasoline, electric, autonomous). To do so, the following resources are deployed: 18 midpoints environmental indicators calculated by LCA, eight product circularity indicators, and numerous leading sustainability indicators. Critical analyses on the usability, time efficiency, scientific soundness, and robustness of each approach are drawn, combining quantitative results generated by each group with the feedback of future engineers.

PurposeAlthough product design is a fundamental element in the transition towards the circular economy, the knowledge of practices, methods and tools oriented to circular product design has not been widely developed. This study aims to contribute to the circular economy research area by investigating and analyzing the main design approaches to circular products and their relationship to new product development.Design/methodology/approachThe authors conducted a systematic review and qualitative analysis of 120 articles. In these studies, the authors analyzed aspects such as design strategies used, the barriers to the adoption of circular product design and the relationships between the phases of new product development processes with circular product design studies.FindingsThe findings revealed that the circular product design approach has added new design strategies to those already recommended by ecodesign, such as multiple use cycles, emotional durability and biomimicry. Furthermore, the results showed that most circular product design articles focus on the planning and concept development phases of the new product development process.Originality/valueIn this article, the authors systematized the findings of an emergent research area: the development of new products for the circular economy. Its main contributions lie in the identification of design strategies, the classification of Design for X approaches, analysis of such approaches during the new product development process and discussion of their main barriers. Finally, this study presents contributions for managers and designers who are starting the transition to a circular strategy.

Sustainable Product Development (SPD) has been gaining increased attention in academia, industry, and policy. Over the past three decades, significant progress has been observed in incorporation of environmental issues into the product development process, through the so-called ecodesign management practices. Nevertheless, systematisation of the SPD practices, which simultaneously consider the environmental, social and economic dimensions of sustainability, is still missing. To address this gap, this research aims to identify the existing SPD management practices in the academic literature, with special focus on how sustainability dimensions are currently being considered, their coverage in relation to key knowledge areas for product development and their applicability across the SPD phases. Through a systematic literature review, 362 practices were identified and further classified according to a classification criteria. While environmental considerations are still the most prominent ones, the research highlights the importance of the early stages of product development for SPD, as well as the key knowledge areas which are currently being covered by the practices, such as sustainability evaluation and sustainability improvement.

The paper proposes an approach called proactive design for sustainability (DfS) in the context of Industry 5.0, for human-centred innovation and environmental sustainability, combined with the technological focus of Industry 4.0. Computer Aided Design (CAD) must integrate sustainability considerations into product development, with the use of Artificial Intelligence (AI), Digital Twins (DTw) and the Internet of Things (IoT) to dynamically monitor and optimise environmental impacts during the design process, with the integration of Key Sustainability Indicators (KSI) into the CAD interface to enable informed decision-making, aligning design parameters with resource availability and environmental constraints. A case study of an autonomous mobile robot (AMR) will show how operational data from the product lifecycle, combined with AI predictions, can reduce energy consumption and emissions.

The growing demand for responsible resource use presents a significant challenge in today’s time-, cost-, and quality-driven product development. Therefore, this paper explores integrating creativity techniques into early development phases to achieve innovative, lightweight, and sustainable designs. Using a case study on extending the useful life of a bicycle trailer, a generic framework is introduced, aligning lightweighting and sustainability objectives in the idea generation process. Lessons learned highlight the critical role of the moderator, the importance of an iterative process, and the need for guidelines on method selection. The findings provide actionable recommendations for fostering sustainable innovation in lightweight design and form a basis for further research on adapting creativity techniques to sustainability goals.

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.

In the context of a circular economy, one can observe that (i) recycling chains are not adapted enough to the end-of-life products they have to process and that (ii) products are not sufficiently well designed either to integrate at best their target recycling chain. Therefore, a synergy between product designers and recycling-chains stakeholders is lacking, mainly due to their weak communication and the time-lag between the product design phase and its end-of-life treatment. Many Design for Recycling approaches coexist in the literature. However, to fully develop a circular economy, Design from Recycling also has to be taken into account. Thus Re-Cycling, a complete circular design approach, is proposed. First, a design for recycling methodology linking recyclability assessment to product design guidelines is proposed. Then, a design from recycling methodology is developed to assess the convenience of using secondary raw materials in the design phase. The recyclability of a smartphone and the convenience of using recycled materials in a new cycle are both analyzed to demonstrate our proposal. The Fairphone 2® and its treatment by the WEEE French takeback scheme are used as a case study.