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A Compilation of Design for Environment


Guidelines

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A Compilation of Design for Environment Guidelines

Cassandra Telenko, cassandra.telenko@me.gatech.edu

Department of Mechanical Engineering and School of Industrial Design, Georgia Institute of

Technology, Atlanta, GA, USA

Julia M. O’Rourke, Carolyn Conner Seepersad, Michael E. Webber

Department of Mechanical Engineering, The University of Texas at Austin, Austin, TX, USA

ABSTRACT

Policymakers, consumers, and industry leaders are increasingly concerned about the

environmental impacts of modern products. In response, product designers seek simple and

effective methods for lowering the environmental footprints of their concepts. Design for

Environment (DfE) is a field of product design methodology that includes tools, methods and

principles to help designers reduce environmental impact. The most powerful and well-known

tool for DfE is life cycle assessment (LCA). LCA requires a fully specified design, however,

which makes it applicable primarily at the end of the design process. Because the decisions with

the greatest environmental impact are made during early design stages when data for a

comprehensive LCA are not yet available, it is important to develop DfE tools that can be

implemented in the early conceptual and embodiment design stages. Based on a broad critical

review of DfE literature and best practices, a set of 76 DfE guidelines are compiled and

reconciled for use in early stage design of products with minimal environmental impact. Select

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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guidelines are illustrated through examples, and several strategies for using the guidelines are

introduced.

1. INTRODUCTION

Environmental factors are receiving heightened attention in product development

activities [4]. Ecodesign or Design for Environment (DfE) is the study and practice of tools,

methods and principles to help designers reduce environmental impact [2,3]. Over the past

decade many tools have been developed to guide designers towards making more

environmentally sound decisions [4–6]. Many of these tools can be classified broadly into two

categories: (1) life cycle assessment (LCA) tools and (2) ecodesign or DfE guidelines. LCA is a

quantitative tool for estimating environmental impacts of a product, and DfE guidelines are

generalizable, best practices informed by LCA [3]. The generalizable nature of guidelines allows

them to be used in the early stages of design when LCAs are not viable.

LCA is a standard approach defined by the ISO 14040 series for quantifying

environmental impacts of a product across its life cycle [7]. A complete life cycle incorporates

processes from extraction of raw materials through end-of-life recycling or disposal of the

product and its constituents. For each stage, the LCA accounts for inputs, such as raw materials

and energy, and outputs such as air, land, and water emissions and other by-products. A

complete LCA helps avoid, detect, and correct inadvertent transfer of harmful environmental

impacts from one life cycle stage to another. For example, addition of a battery and a motor to

create a hybrid vehicle reduces the environmental effects during the vehicle’s useful life.

However, an LCA reveals that non-trivial environmental effects are increased in other stages of a

hybrid vehicle’s life cycle because of extra parts and toxic materials. Designers find LCA useful

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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for quantitatively assessing environmentally-related tradeoffs as part of the product development

process.

A comprehensive LCA, however, requires significant amounts of time and highly detailed

data describing the final product [8,9]. For example, LCA requires complete information on the

mass of each type of material in the final product, and precise quantities of material and energy

inputs and outputs of each stage of the production process. This information is typically

available only in the final stages of product development, after most product design decisions

have been made.

As shown in Figure 1, LCA is primarily a retrospective design tool for modifying bills of

materials, comparing existing products or processes, or designing a variant of an existing

product. Limited data quality and availability, as well as temporal and spatial factors, can make

full LCAs difficult for companies without expertise or ample proprietary data [10–14].

Therefore, more qualitative life cycle thinking tools, such as guidelines, informed by full LCAs,

are often utilized in the earlier stages of design [6].

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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Figure 1: The Product Development Stages, Showing LCA as a Retrospective Tool and DfE

Guidelines as a Concurrent Design Tool [15]

DfE guidelines have been developed to guide designers in creating product concepts and

layouts when lack of time and detailed information prohibit a full LCA. Examples [16,17] of

guidelines include “ensuring rapid warm up and power down for energy efficiency” and

“ensuring easy access to fasteners and joints for disassembly and recycling.” DfE guidelines

often reflect lessons learned from LCA that pinpoint flaws or potential improvements in

candidate designs for improved environmental impact. They also promote consistency and

systematization between design projects, facilitate communication of new discoveries, and

provide an important set of environmental solutions to complement or replace unavailable LCA

data [3].

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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The difficulty with DfE guidelines is that they are scattered throughout the literature, in

various forms and levels of abstraction, and they often focus only on specific life cycle stages,

products, or industries [18,19]. Also, as noted by Ramani et al. [2], some guidelines are so

specific that they are too prescriptive for novel design. A comprehensive set of DfE guidelines is

needed that synthesizes best practices from across these various sources and organizes them in a

form that is immediately useful to designers in a broad range of industries. In this paper, the

primary objective is to compile and present such a set of guidelines. The resulting guidelines and

examples are presented in Section 4. Section 2 summarizes the existing set of literature, and

Section 3 describes the research approach to reconciling guidelines. Section 5 discusses a

number of ways designers can use DfE guidelines in practice.

2. EXISTING DFE GUIDELINES

The goal of this research is to establish a comprehensive set of DfE guidelines that designers

from a variety of industries can use immediately to reduce the environmental impact of designs

throughout their life cycles. Published lists of DfE guidelines typically fall short of this goal, by

presenting guidelines that are too abstract to be useful; by focusing only on specific life cycle

stages; or by tailoring guidelines too closely to a particular product, industry, or stakeholder.

Thus, the central contribution of this work is to reconcile existing knowledge in a format that can

be used for advancing DfE research and education.

Many published lists of DfE guidelines focus on a single life cycle stage, often in the form of

Design for X strategies [3,20–23]. Examples include Design for Disassembly, Design for

Recycling, and Design for Energy Efficiency. End-of-life approaches to reducing environmental

impact, such as recycling, are relatively well established in the literature while other approaches,

such as guiding user behavior, are still being developed [18,24]. Because these types of
Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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guidelines have been developed and published separately, the risk is that the designer may focus

on a few simple redesign avenues and lose the holistic, life cycle perspective provided by a more

comprehensive set of DfE guidelines.

Many researchers and companies have developed sets of industry-specific guidelines, rules,

and checklists aimed at reducing the environmental impact of designs [25–28]. Volvo, for

example, instituted a Black, Grey, and White list of prohibited, cautionary, and clean materials in

the late 1980s/early 1990s [29]. Philips has a general list of DfE guidelines [30,31]. Likewise,

Siemens created its own list of 40 DfE principles [32]. Many of these guidelines assume

technological solutions; for example, Hewlett Packard’s mobile products follow specific rules for

electronic display, such as “Set display brightness to lowest comfort level to conserve energy /

battery life” [16]. Because the rule is solution-specific, it confines the designer to a specific

technology, such as electronic displays, rather than alternative, innovative solutions such as

organic displays that reflect ambient light. If the guideline were more general and applicable to a

broader range of products, it would encourage designers to utilize a component with best-in-class

energy efficiency. This example illustrates the difficulty with industry- or product-specific DfE

guidelines and suggests that guidelines may be more useful if they apply to a range of products.

Similarly, many regulations are being developed for products in specific regions and

industries. The Restriction of Hazardous Substances (ROHS) and Waste Electrical and Electronic

Equipment (WEEE) directives are two widely accepted sets of rules for prohibited materials in

electronics [33]. The European Eco-Label [34] provides a few product-specific guidelines and

requires a full LCA. The McDonough Braungart Design Chemistry Certification [35] offers a

checklist point system to certify different levels of products, most of which are in the material

and chemical domains. The Environmental Protection Agency’s Energy Star certification verifies

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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best-in-class energy efficient products and homes [36]. The U.S. Green Building Council’s

Leadership in Energy and Environmental Design (LEED) certification program and other green

building certifications offer advice and performance targets for a number of environmental

impact reductions [37]. While these are useful requirements for a designer to meet, they do not

provide the guidance offered by sets of DfE guidelines in realizing new, environmentally friendly

concepts.

In contrast to the industry- and product-specific sets of guidelines, some sets of DfE

guidelines are extremely abstract. These lists typically articulate high-level goals of creating

ecologically beneficial products. Anastas and Zimmerman [38], along with McDonough and

Braungart [39,40], provide lists of abstract principles, such as “it is better to prevent waste than

to treat or clean up waste after it is formed.” Luttrop et al. [41] created a list of ten generic

principles which bring DfE to an intermediate level from which each product designer derives a

set of specialized guidelines. Although these principles cover the entire scope of Figure 1, the

level of abstraction is best complemented with more actionable guidelines.

Finally, some DfE guidelines are focused on managers or manufacturing process specialists,

rather than product designers. These guidelines can include everything from corporate attitude

and marketing to the operation of processing plants [20–23,42]. To emphasize the fact that the

environmental impact of a product is ultimately determined by a broad range of factors, many

guidelines within these lists begin to stray from an emphasis on the product designer. It is

important for companies to adopt an environmental management system (EMS) and for

designers to acquire knowledge of production processes and supply chains [43,44], but the

purpose of this literature review is to create a set of DfE guidelines geared towards a designer.

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For example, a designer does not need a guideline for production operations, but does need a

guideline for facilitating good production operations through the design of the product.

Designers are left to sift through these general principles, Design for X guidelines, and

product-specific checklists to create their own version of DfE. There is no consolidated set of

guidelines that can be used by the product designer. In the following section, a methodology is

presented for creating such a comprehensive set of guidelines from these sources.

3. METHOD FOR COMPILING A SET OF DFE GUIDELINES

Research began by compiling the principles, guidelines, and checklists described in the

academic literature and industry reports and manuals. Section 2 summarized general findings and

discrepancies across these sources. A snowball search method was utilized. Initial searches using

combinations of the terms: “rule-of-thumb” “principles”, “guidelines”, “checklists”, “design for

environment”, “DFE”, “eco-design”, “sustainable design”, and various synonymous phrases.

Additional literature findings were revealed through the bibliography or subsequent citations

listed by the Google Scholar search engine. Twenty-two sources were included in the study. To

merge the various types and levels of statements into a comprehensive set of guidelines, quoted

statements were synthesized and organized into a hierarchy using a mind map [45]. During the

mind-mapping process, each guideline was formulated to meet four criteria. The criteria are

defined as follows:

o Designer-oriented: the guideline must be within the scope of a product designer

o Actionable: the guideline must propose an avenue for improving the design

o General: the guideline must apply to a broad range of products

o Positive Imperative: the guideline must focus on creating the best solution possible

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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In this section, the four criteria are described in greater detail and the overall methodology for

establishing the comprehensive set of guidelines is summarized. Fu et al. [46] provide a review

of design principles theory and validation in general, and their findings also suggest that

principle are derive largely from experience and are formed at varying levels of granularity given

the application. The critera for this set of guidelines are aimed at product designers who make

functional, architectural and aesthetic decisions.

The designer-oriented criterion defines the audience for this set of guidelines. It requires

that each guideline be formulated to direct designers, rather than managers or other stakeholders.

When reformulating guidelines to be more designer-oriented, it was helpful to refer to Pahl and

Beitz’s [15] list of the types of decisions typically made by a product designer: 1) overall layout,

2) form and types of components, 3) selection of materials, and 4) communication with the user

or manufacturer. An example of a guideline that did not meet the designer-oriented criterion is:

“Motivate the sales department to avoid environmentally-harmful forms of transport”[21],

because it is directed at stakeholders other than designers.

The actionable criterion requires that guidelines provide designers with summary-level tasks

for improving a product. High-level strategies, such as “Ensure long life,” articulate useful goals

but provide no advice on how to meet those goals. To make this strategy more actionable, it is

broken into potential avenues for achieving it, such as “Ensure that aesthetic life meets technical

life” and “Plan for efficiency improvements.” Goal-oriented DfE strategies are maintained as a

means of sorting the more actionable guidelines. The actionability of a guideline must be

balanced with general applicability, which is the focus of the next criterion.

The general criterion requires that guidelines apply to a variety of product categories and

design problems. To make guidelines actionable, practitioners and legislative bodies often create

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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solution-specific guidelines, such as “avoid hydrocarbons that cause summer smog from

lacquers, solvents, and plastic foams.” Focusing on lists of materials can lead to the use of

unevaluated materials that are worse for environmental or human health. Writing the guideline as

“specify environmentally benign materials” increases the general utility of the guideline and

focuses on the need and subsequent action. In another example, “For hygiene, use a

laminate/recycled plastic laminated by virgin plastic” [21] was reconciled as, “Layer recycled

and virgin material where virgin material is necessary” to make the guideline applicable to a

wide range of materials and situations, rather than just plastics and food products. Throughout

the study, adjectives such as “ozone-depleting” and “carbon-creating” are combined under the

broader category of “hazardous” and reinterpreted as “clean.” Directions for using natural

materials, or not using synthetic or non-ferrous metals, are generalized to terms [20,22,23,47–51]

such as renewable, recyclable, and low-embodied energy. As an example of an industry-specific

rule, furniture designers are encouraged to specify sustainably-forested wood [20,26]. This rule is

subsumed under the more general guideline, “Specifying renewable materials.”

Using the positive imperative form helps focus the designer on positive possibilities,

including what to use rather than what not to use. Many current design guidelines are of the

form: “Do not…” or “Avoid… toxic or hazardous substances [22].” As noted above, “Specify

environmentally benign materials” [20–23,42,47–51] is only a slight modification of the

guideline, but places immediate focus on finding new solutions rather than solving old problems.

In another example, “avoid transport by air” is reconciled as “Source from suppliers with low

transportation impacts.”

These criteria were applied in the context of a mind-mapping process [45] for categorizing

and synthesizing the guidelines gathered from the literature. A mind map is a visual recording of

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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a brainstorming session. The center of a mind map contains the overall function or goal of the

brainstorming session. Ideas and possible solutions are drawn from the center and grouped into

sets of similar concepts. For the purposes of this research, “Design for Environment” was placed

as the overall objective at the center of the mind map, and guidelines fulfilling this objective

were placed as sub-branches. Figure 2 presents a portion of the final mind map that emerged

from the literature study. The use of a mind map facilitated identifying interdependencies and

overlapping guidelines, arranging the guidelines in a hierarchy, and ensuring similar levels of

specificity across the mind map. For example, “lighter materials”[22] and “reduce mass of

components”[52] became “specify lightweight materials and components.” Guidelines to avoid

technical life that is greater than aesthetic life [48] or “increase aesthetic life” [21] or utilize

“timeless” or “classic” design [49] became reconciled as “improve aesthetics and functionality to

ensure the aesthetic life is equal to the technical life.”

The mind map originally resulted in four levels of guidelines branching from the central

objective “Design for Environment.” The first level contained general strategies for DfE, such as

“material and energy inputs should be renewable rather than depleting”[38]. The second level

contained either further sub-strategies or guidelines, such as “technical life should not exceed

aesthetic life”[48]. The third level contained either rules stemming from guidelines or guidelines

stemming from sub-strategies, such as “plan for energy upgrades”[17,20]. The lowest level

consisted of product-specific rules, which were abstracted to general guidelines as previously

discussed in this section. Overlapping strategies and sub-strategies were reformulated into a

single, combined strategy using the criteria. Equivalent guidelines were combined into one

encompassing guideline, and all strategies and guidelines were reviewed to meet the four criteria:

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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designer-oriented, actionable, general, and positive imperative. The methodology resulted in 6

DfE strategies and 76 guidelines.

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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Figure 2: Final DfE Mind Map (abridged)

4. DFE GUIDELINES

Table 1 shows the full compilation of DfE guidelines. The guidelines are rooted in the literature (Section 2),

but the consolidation of guidelines from disparate sources, the hierarchical arrangement into strategies and

guidelines, and the wording of each strategy and guideline is distinctive to this work. Strategies are re-

conceptualized from the mind map and literature review to fit the criteria: A and B for resource and process

selection, C for production and transportation, D for use, E for extended life and F for disassembly. Because

guidelines stem from LCA, these strategies tend to represent the major stages and flows of the product life cycle

[2,6]. The organization by strategy is meant to aid the reader in understanding overarching goals of the

guidelines. Nevertheless, synergies and overlaps exist such that guidelines may be appropriate for multiple

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404, Page 13


strategies. In particular, guidelines under Strategy F that support ease of disassembly also facilitate many of the

other guidelines and strategies. Additionally, guidelines under Strategy E, increasing the life of a product,

should be compared with Strategy D and the needs of efficient production and product operation.

Terms used in the guidelines indicate broad applications of sustainability concepts. As in Oehlberg et al.

[18], guidelines that apply to efficiency and consumption may be misconstrued as energy-focused. “Resources”

encompasses material, food, water, energy and other resources. The term “materials” can include engineering

materials, food, and water. “Hazardous” is the opposite of “beneficial”, meaning that a material itself has

negative health effects upon the environment or humans. The term “pollutant” may overlap with “hazardous”,

but may encompass nuances, such as noise pollution, or more indirectly hazardous outputs, such as carbon

dioxide. “Outputs” may refer to any material or energy flow from any process during the product’s life cycle.

“Recycled” does not only refer to re-processed materials, but materials that can be reused with little to no

additional processing.

The following subsections describe products that embody one or more of the guidelines. Each

subsection focuses on one strategy and multiple related guidelines. These examples illustrate a small, product-

focused selection of the potential applications of DfE guidelines and sustainability concepts. Although the

guidelines are informed by LCA insights, the example designs and guidelines are not all-encompassing. New

guidelines are likely to be discovered, and the guidelines themselves involve difficult tradeoffs that change with

context. For example, materials that are bio-degradable (guideline #9) might make more sense in emerging

economies where waste collection does not occur, but recyclable materials (guideline #1) may be better in

communities with strong recycling systems.

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404, Page 14


Table 1: DfE guidelines
A. Maximize availability of resources:[3,20–23,32,38,41,42,47–
51,53] 38. Minimize start up and power down time
1. Specify renewable and abundant resources 39. Interconnect available flows of energy and materials
2. Specify recyclable or recycled resources 40. Maximize system efficiency for a range of real world
3. Layer recycled and virgin material where virgin material conditions
is necessary 41. Create shared or service systems that de-materialize
4. Employ common and remanufactured components 42. Harmonize the operation with users’ daily activities within
across models the product and its environment
5. Specify compatible materials and fasteners for recycling 43. Permit users to turn off systems in part or whole
6. Minimize the variety of materials in the product and its 44. Reveal how much resource is being consumed
subassemblies 45. Incorporate intuitive controls for resource-saving features
B. Maximize healthy inputs and outputs:[3,15,20–23,41,42,47– 46. Incorporate features that prevent or discourage waste of
51,53] materials by the user
7. Contain pollutants and hazardous materials for reuse or 47. Automatically reset the product to its most efficient
processing setting
8. Specify environmentally benign materials 48. Employ transformation or multi-functionality
9. Create biodegradable outputs E. Maximize technical and aesthetic life of the product and
10. Specify resources with low emissions components:[3,15,20–23,32,41,48,49,51,53,57]
11. Include labels and instructions for safe handling of toxic 49. Reutilize resource intensive components
materials 50. Plan for ongoing efficiency improvements
12. Concentrate pollutants and hazardous materials for easy 51. Improve aesthetics and functionality to ensure the
removal and treatment aesthetic life is equal to the technical life
13. Recover emissions and outputs 52. Minimize required maintenance
C. Minimize use of resources in production and 53. Protect products from dirt, corrosion, and wear
transportation phases: [17,20–23,32,38,42,48,50,53] 54. Indicate through the product how parts are maintained
14. Replace the functions and appeals of packaging through 55. Minimize the number of service and inspection tools
the product’s form 56. Facilitate testing of components
15. Employ folding, nesting or disassembly to ship and store 57. Allow for repetitive dis- and re- assembly
products in a compact state 58. Increase the value with age
16. Apply structural techniques and materials that minimize 59. Communicate durability and reliability through the form
the total volume of material F. Facilitate upgrading and reuse of components: [3,15,20–
17. Specify lightweight materials and components 23,32,38,41,42,47–51,53,58]
18. Structure the product to avoid rejects and minimize 60. Make wear detectable for repair and upgrade
material waste in production 61. Indicate through the product how it should be opened
19. Minimize the number of components 62. Ensure that joints and fasteners are easily accessible
20. Specify materials with low-intensity production and 63. Facilitate upgrading and reuse of components that
agriculture experience rapid change
21. Specify materials that do not require additional surface 64. Maintain stability and part placement during
treatment of inks disassembly/assembly
22. Exploit intrinsic properties of materials 65. Minimize the number of tools required for
23. Specify clean production processes within the supply disassembly/assembly
chain 66. Minimize destructive disassembly and its effects
24. Employ as few manufacturing steps as possible 67. Ensure reusable parts can be cleaned easily and without
25. Source from suppliers with low transportation impacts damage
D. Minimize consumption of resources during operation: 68. Make incompatible materials easily separated
[3,15,20–24,38,41,42,48,49,51,53–56] 69. Make component interfaces simply and reversibly
26. Implement reusable supplies separable
27. Incorporate timed, noticeable incentives into operation 70. Organize in hierarchical modules by aesthetic, repair,
28. Minimize energy and material loss and end-of-life protocol
29. Minimize the volume and weight of materials to which 71. Implement reusable/swappable platforms, modules, and
energy is transferred components
30. Optimize the rate and duration of resource use to the 72. Specify adhesives, labels, surface coatings, pigments
task that are compatible with cleaning during and after the
31. Provide discrete quantities of resources useful life
32. Provide automatic or manual tuning capabilities 73. Employ one disassembly/assembly direction without
33. Indicate the current state of processes reorientation
34. Create separate modules for tasks with different ideal 74. Minimize the number and length of operations for
solutions detachment
35. Support complex decision-making by the user 75. Mark materials in molds with types and reutilization
36. Specify best-in-class efficiency components protocol
37. Incorporate partial operation to disengage subsystems 76. Use a shallow or open structure for easy access to sub-
that are not in use assemblies

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404, Page 15


4.1 Strategy A: Maximize Availability of Resources

Strategy A aims to address resource depletion by encouraging reuse and renewability of

resources. The guidelines organized under this strategy apply to every aspect of the product,

including consumables and packaging. Proper application of these guidelines requires some

investigation into current material databases and supply chains to make informed decisions.

Guideline 5, for example, would suggest using fasteners that are the same metal, plastic, or other

material as the main body. That way, the product does not have to be disassembled and parts

separated. Additionally, adhesives could be water-soluble so that the material quality is easily

reprocessed. Both of these guidelines are aimed at increasing the likelihood of material being

recycled as stock for new applications.

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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Figure 3: Xerox® Uses Remanufactured Modules (Adapted from [59,60])

Guideline 4: Employ common and remanufactured components across models.

By using common parts and remanufactured components, a designer ensures that those parts

are available for additional lifecycles and avoids the unnecessary material and manufacturing

costs associated with additional virgin components. The designer may also create a product line

that supports reuse by enabling interchangeable parts.

One example of designing with remanufactured components comes from the redesign of the

Rank-Xerox® photocopiers in the 1990s [50]. Designers completely redesigned the architecture

of their photocopiers, making them able to accommodate remanufactured modules from current

and previously introduced products, shown in Figure 3 [61]. The remanufactured and conversion

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models use remanufactured parts, such as paper trays and common cartridges [62]. In 2009, 70-

90% of components by mass were reused [63].

4.2 Strategy B: Maximize Healthy Inputs and Outputs

Healthy inputs and outputs are those that cause minimal environmental degradation or

adverse effects on human health; in fact, these inputs and outputs should improve environmental

and human health. This strategy requires elimination of hazardous substances and pollutants as

well as the conversion of waste to useful materials for products and ecosystems. Like strategy A,

strategy B applies to every aspect of the product, including consumables and packaging.

Guideline 10: Specify resources with low emissions.

Guideline 10 focuses on emissions from energy sources. Often, a product’s largest

environmental impact is dependent on the amount and type of energy consumed during its use

phase. By using clean energy sources, such as solar and wind power, a product can avoid power

plant emissions. Other energy source considerations, such as choosing rechargeable batteries

rather than disposable ones, would also fall under this guideline. Thus, a product will result in

the disposal of one set of batteries, and not dozens, thereby reducing toxic waste at end-of-life.

The Seiko Kinetic® Auto Relay, shown in Figure 4, exhibits both aspects of this strategy; it

has no batteries and no external chargers. Seiko’s watch is powered by the kinetic energy of the

wearer’s movement, a readily available and clean energy source (Guideline 1). The watch is

charged after a few side-to-side motions, and operated by an oscillating weight [64]. An

additional power saving feature is that hand motion stops after the watch is stationary for 72

hours (Guidelines 37, 42, and 43). The watch maintains the correct time internally for up to 4

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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years of inaction. Within those four years, the watch can be shaken to return to the correct time

[64].

Figure 4: Wearer’s Movement Powers the Seiko Kinetic® Auto Relay [65]

4.3 Strategy C: Minimize Use of Resources in Production and Transportation Phases

Strategy C encourages designers to think about how product attributes affect the efficiencies

of seemingly unrelated processes. Guidelines for fulfilling strategy C provide direction in

structuring and sizing products to reduce material waste in production and reduce the load and

number of shipments to lower fuel use and emissions.

Guideline 16: Apply structural techniques and materials that minimize the total volume of

material.

Guideline 16 challenges the designer to find alternatives to over-designing a product. The

emphasis lies in rethinking over-designed and “one size fits all” [38] solutions. Rather than

increasing thickness or size, designers should try to specify lightweight and high strength

materials as well as investigate sturdier and more compact geometries. Figure 5 shows the Black

and Decker® Leaf Hog™, which uses ribbing to achieve not only structural rigidity but also

internal part placements. This design also embodies general best practices for manufacturing; the

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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creation of thinner walls aids the injection molding process, promotes cooling of the newly

molded part, and reduces shrinking, consequently improving the efficient use of manufacturing

resources.

Figure 5: The Black and Decker® Leaf Hog™ Uses a Ribbed Structure to Increase Strength

and Reduce Material Use

Guideline 22: Exploit intrinsic properties of materials.

Guideline 22 reminds designers to fully utilize the qualities of materials, recycled or natural.

Treatment of materials, such as forming and pigmenting, adds extra and potentially harmful

processing steps. However, by making use of unique textures, color combinations, and

intermixed patterns of a material, a designer can realize untapped potential, forgo additional

production steps, and divert valuable material from landfills.

An example of not just recycled, but reused material comes from Bitters Company. They

design doormats and keychains using scrap foam rubber produced during the manufacture of Flip

Flops. Reusing waste from the manufacturing stage (Guidelines 2 & 13), Bitters Company

maintains the original coloring to create patterns in their final doormat or keychain. Figure 6

shows the clever use of the rubber foam for a floating keychain [66].
Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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Figure 6: Bitters Company Uses the Original Coloring and Low Density of Flip Flop Scraps

to Make Products such as Floating Keychains and Doormats [66]

4.4 Strategy D: Minimize Consumption of Resources During Operation

Strategy D concerns the promotion of features that increase the energy- and materials-

efficiency of designs, as well as features that help the user conserve resources while using the

design.

Guideline 39: Interconnect available flows of energy and materials.

Guideline 39 makes use of nearby resources, such as waste material and energy. Some

famous and broader applications of this guideline are solar power and regenerative braking. Solar

power makes use of the prime source of energy available to the planet, but incorporating a solar-

powered system in a design requires the designer to be mindful of product exposure to sunlight.

Regenerative braking recovers expended energy. Instead of braking a car by disk or drum brakes

and losing kinetic energy as heat, the electric generator is reversed from powering the wheels to

being powered by, and effectively slowing, the wheels.

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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Retrofit products, such as the SinkPositive in Figure 7, are now being marketed to the

environmentally conscious consumer. One flush of a toilet sends one gallon or more of potable

water down the drain. Washing one’s hands after using the toilet causes additional loss of this

increasingly important commodity. SinkPositive combines the two interlinked functions by

connecting a sink to a toilet tank. After a user flushes the toilet, replacement water is fed through

an added faucet and used for hand washing prior to filling the tank, thereby reducing water use

relative to a bathroom with a separate toilet and sink.

Figure 7: SinkPositive Diverts Tank Water Through a Faucet [40]

Guideline 46: Incorporate features that prevent or discourage waste of materials by the user.

Guideline 46 requires designers to be more conscious of how their product will be used or

misused, and the aspects of material use that can be guided by design. A few examples of this

guideline are found in products with calibration marks for a user to measure the correct amount

of water, washing powder, or coffee they place into their product [21,42]. Another instance of

how products can be designed to aid the user is the incorporation of funnels to prevent spillage

[21,42].

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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Figure 8: The ECO kettle™ Responds to User Habits and Helps Users Heat Only What

They Need [67]

A good example of this guideline is the ECO kettle™ in Figure 8. The ECO kettle™

accounts for a common mistake – heating too much water. Combining guidelines 29 and 34, the

designers partitioned the kettle into separate storage and heating compartments, with gradients to

measure the contents of each compartment. Most importantly, this allows users to continue their

habit of leaving extra water in the kettle (not wanting to refill the kettle every time they heat

water) but also begin a habit of heating the correct amount of water. Thus, energy is saved, and

environmentally-responsible habits are encouraged.

4.5 Strategy E: Maximize Technical and Aesthetic Life of the Product and Components

Extending the life of a product avoids the life cycle impacts of a replacement product and

postpones the impacts associated with the end of life of the existing product. Strategy E can be

addressed using two important approaches: (1) increasing the durability of the product to extend

its useful life, and (2) enabling the product to be easily updated to meet current best practices. In

this way, use of old, inefficient technology is not prolonged. Since the durable product can be

updated in parts, designers have time to develop new, innovative, environmental solutions and/or
Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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incorporate the latest environmentally friendly technology. This strategy may require the

development of new business policies and operations, such as product service systems [68]. It is

also important to note that Strategy E, requires balance with Strategy D (minimizing resource

consumption during use). For example, the work by Gutowski et al. [69] show that the efficiency

improvements of new electrical components save more energy than remanufacturing old

electronics.

Guideline 49: Reutilize resource intensive components

Guideline 50: Plan for on-going efficiency improvements

An example of a product service system is the creation of clothing rental sites, like Rent

the Runway. These sites allow customers to rent designer clothing, such as formal wear, that

may be worn only once at affordable rates and then send the clothing back for maintenance.

Thus, the water and human and transportation resources used in manufacturing additional

clothing in other parts of the world are saved in favor of a single dress or other piece used by

multiple customers. The dresses are reused (guideline 49) and the system accounts for the high

turnover and low utilization of clothing (guideline 50).

Guideline 51: Improve aesthetics and functionality to ensure the aesthetic life is equal to the

technical life.

Guideline51 facilitate the longevity of an initial design in the hands of a user. A physically

durable component or product is useless if a consumer replaces it before it becomes obsolete.

Created with a “classic” or updateable design, a product can stand the test of time in usefulness

and appeal to the consumer.

One example of such a classic and updateable design is the IKEA POÄNG Chair, shown in

Figure 9, released as the POEM chair in 1977. Owners of the original chair still have a modern
Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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design as the chair design has remained nearly the same, with only changes in the cushions

and covers over time. This aesthetically and structurally long-lasting design allows for

continual renewal of the product by simply replacing the cover or cushion as needed.

Figure 9: The IKEA POANG Chair has been Successful Since 1977 [70]

4.6 Strategy F: Facilitate Upgrading and Reuse of Components

Recycling, remanufacturing, reuse, repair, and upgrading can be facilitated by incorporating

these features for disassembly, separation, and purification. These features are often found as

structural solutions complementing strategies A-E. Very often, Strategies E and F occur in

tandem, but some guidelines, such as 60, “Make wear detectable…”, can conflict with Strategy E

by worsening aesthetics. Furthermore, this guideline in tandem with #63, “Facilitate upgrading

and reuse of components that experience rapid change,” often supports Strategy D for reducing

consumption during the use phase because they can help keep the product operating efficiently

over time.

Guideline 51: Improve aesthetics and functionality to ensure the aesthetic life is equal to the

technical life.

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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Guideline 71: Implement reusable/swappable platforms, modules, and components

For example, aesthetic maintenance is supported by modular design in Ford’s Model U

Concept Car from 2003. Figure 10 shows the interior of Ford’s design using modular structures

and common components for aesthetics. The interior is “uncluttered” to allow consumers to

modify the interior as they choose. Upholstery, slots and electronic connections are arranged so

the user can insert and remove both electronics and finishings. It is a long-term, upgradeable

investment, designed to accommodate changing preferences and needs [71]. The design includes

both recyclable and biodegradable materials. The Ford Model U’s architecture helps a user

customize the base, the floor, and the fabric. Modules that are removed during the use and

upgrade of the vehicle are designed to be easily accessible and standardized. At end-of-life,

materials are organized into recyclable and biodegradable waste.

Figure 10: Ford Model U Concept Car has a Modular and Upgradeable Interior [72]

Guideline 50: Plan for ongoing efficiency improvements; and

Guideline 71: Implement reusable/swappable platforms, modules, and components

Guideline 71 tries to avoid a waste problem that many consumers experience: a product

contains many components and features; one of those becomes obsolete or breaks down; and the

consumer is forced to purchase an entirely new product. This situation is not only irritating to

consumers, but creates an unnecessary amount of waste, rendering operational components

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useless. Evidence of this phenomenon is apparent in the electronics industry, where cell phones

may be replaced yearly.

An exemplar modular, reusable, upgradeable design is the desktop computer. Every tower

has standard slots and sizes for DVD ROMs, CD ROMs, and video cards. Motherboards come

with the same slots, with options to upgrade and change memory types. Whole computers can be

built at home or by independent parties from spare parts – saving assembly energy, reducing

waste of old parts, and allowing upgrades to more energy efficient components.

5. APPROACHES TO USING DFE GUIDELINES

The examples in Section 4 demonstrate design solutions that follow DfE guidelines. In

contrast, this section discusses the many ways design practitioners and researchers use

guidelines, or could use guidelines in the future. The purpose of this section is to summarize the

variety of methods for using guidelines, in addition to potential advantages and disadvantages of

these approaches. For all methods, there may be cases where a change to better meet a guideline

may prevent application of another guideline less well (for instance, if a lighter weight material

is not recyclable). The designer must always have a holistic view of the product's life cycle and

consider the possible unintended consequences of implementing design changes that would

better meet a guideline.

Approach 1: Identifying a DfE strategy and implementing relevant guidelines

It is difficult to implement some of the guidelines simultaneously; for example, the most

lightweight material for a particular high-strength application may also be difficult to recycle.

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Experts will often choose high-level DfE strategies based on known challenges with a particular

product and then refer to the corresponding guidelines [73,74].

One example of this approach is the LiDS wheel or DfE Strategy Wheel by Van Hemel [75].

Practitioners of the LiDS wheel evaluate typologies of strategies and guidelines, with each of 8

typologies represented using axes in a spider chart. By drawing current and desired levels of

performance in relation to these strategies, companies and designers can create targets for

themselves. After this analysis and reflection, detailed use of guidelines, such as those presented

in this paper, may be helpful for achieving those targets.

Baeiswyl and Eppinger [73] take a similar approach in that they conceive of DfE strategies of

interest as being dictated by the DfE goals of the project and the largest expected environmental

impact areas. For instance, if the design team is trying to become compliant with a new

regulation mandating recycling, then guidelines related to increasing recyclability and using

recycled materials would likely be selected. Baeriswly and Eppinger [73] also discuss how

Studio 7.5 used this approach to design a sustainable office chair for the furniture company

Herman Miller. They describe how Herman Miller chose to focus on sustainable material

selection, easy product disassembly, and recyclability because they recognized at the outset that

the main environmental impacts associated with their office furniture occur during the material,

product and recovery life cycle stages [67]. This approach inspired them to make many

environmentally-beneficial changes to their designs, including, for instance, the decision to use

two materials for the chair’s spine that can be recycled without separation, as opposed to a

previous design that specified the use of dissimilar materials that could not be recycled together

[67].

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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Strategically selecting a subset of guidelines allows for faster achievement of companies’

environmental goals and reduces time spent on portions of the design that do not significantly

affect its overall environmental impact. Conversely, when relying on expert knowledge and

intuition, one must assume experts know which guidelines would yield the most fruitful results.

This could be an incorrect assumption and could cause high-impact opportunities outside of that

strategic design space to be discounted. If the company or expert is biased toward a particular

type of solution (ex. increasing recyclability), they might overrate the importance of related types

of environmental impacts, and they might overlook guidelines that would provide more

innovative avenues for reducing environmental impact overall.

Approach 2: Using guidelines as idea generators.

Designers could use the DfE strategies and guidelines as a foundation for ideation and

concept generation. A mindmap of guidelines, similar to Figure 2, could be provided, and design

teams could be encouraged to use the guidelines as idea generators for new concepts that meet

the specified guideline better than the original design. Teams could be encouraged to develop

concepts for every guideline listed, thereby forcing them to consider the entire life cycle impact

of their design and explore a broader sustainable design space. Rather than getting lost in details

- as might occur if designers were focused on very specific guidelines for one life cycle stage, or

if they were trying to accrue data for an LCA - the DfE guidelines facilitate the development of a

holistic perspective of environmental impact that is useful in the early stages of conceptual

design. When using the guidelines during concept generation, there may be a danger of fixating

on particular guidelines due to design team members' biases or the ease of which ideas can be

generated to meet particular guidelines. For example, designers of staplers may focus on

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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minimizing stapling error or choosing recyclable materials, but patents for staple-free staplers

were first obtained in 1913 [76]. There are now multiple brands of staplers that punch and fold

the paper as a "staple" (guidelines 13 and 49) marketed as eco-friendly [77]. Many means of

holistic implementation of the guidelines have yet to be examined in repeatable studies, a task for

future work.

Nevertheless, this approach appears promising because it takes advantage of the fact that the

guidelines presented in this work are both broad and detailed. These guidelines apply to all life

cycle stages, and they provide a number of different strategies a designer could use to reduce

environmental impact in each of these stages. For instance, guidelines focused on multiple life

cycle phases can be used to prompt designers to consider the life cycle impact of the product

they are designing in a holistic way and promote higher-level systems thinking regarding

environmental impact. For example, Vallet et al. [78] studied the DfE practices of experts

redesigning a razor. They showed that by starting with an environmental strategy, designers may

focus on redesigning aspects of a product that have limited influence on the overall

environmental impact, instead of aspects of the product with potentially larger impacts (for

razors, it may be water used while shaving).

Approach 3: Using an expert knowledge database to select relevant guidelines based upon

desired DfE strategy and design stage.

Work from other researchers has sought to automate the process of selecting relevant

guidelines using input from the designer. This approach makes the process of selecting relevant

guidelines quicker, and it avoids the need for expert input. Researchers from the University of

Grenoble [79], for instance, have developed a design tool called Synergico, which contains 59

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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design guidelines related to energy efficiency. Synergico has different filters corresponding to,

for instance, the design stage (conceptual vs. detailed design) and the designer’s department

(mechanical design vs. marketing). Designers answer questions related to these filters, and

Synergico presents a small set of relevant guidelines. The researchers used Synergico to identify

sustainable redesign avenues for a postage meter, a device that seals envelopes, determines the

appropriate amount of postage for the letter, applies the stamps, and charges a bank account.

Synergico helped the designers identify four efficiency-related guidelines to consider during the

redesign. Although some of the guidelines could not be fully implemented, the identification of

these guidelines prompted the designers to consider strategies to meet the guidelines and

comment on how they could or could not meet the guideline better in their final design. Because

of the influence of the guidelines, the designers identified the possibility of incorporating a

standby mode in the default settings of the postage meter.

Similarly, Vargas Hernandez et al. [80] developed GREENSYS, a tool to help designers

identify relevant sustainable design tools and methods. GREENSYS prompts designers with a

series of questions that are used to screen the database of possible sustainable design tools and/or

guidelines that may be of interest. The three required questions deal with: (1) the design

objective, (2) the life cycle stage of interest, and (3) the stage of the design process. There are

also optional questions concerning designers’ desired DfE strategies.

An advantage of this approach is that it is time efficient. Designers are presented only with

guidelines that are likely to be of immediate use to them, either because they are interested only

in a particular type of sustainability solution (Design for Recycling), have control over only one

aspect of a design (electronics), or need a particular level of detail or abstraction.

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Nevertheless, a disadvantage is that the holistic life cycle perspective is lost. When

implemented this way, designers may be in danger of fixating on the first sustainable design

problem or solution that comes to mind; for instance, they might focus only on improving

recyclability. This effect is more pronounced for this approach than in Approach 1, discussed

above, because designers may not see the other guidelines and the many alternative options that

may be available to them to lower the overall environmental impact of a product from a systems

perspective.

Approach 4: Using the set of guidelines to evaluate concepts

Complete sets of guidelines can serve as a proxy for full or streamlined LCAs. This practice

has a basis in early streamlined LCA tools that used checklists or matrices of questions for

evaluating early-stage concepts. O’Rourke and Seepersad [81] used a previous compilation of

DfE guidelines presented in this work to compare the life cycle impacts of nine bioinspired

designs and their functionally-equivalent non-bioinspired competitors. Moderately-detailed

information on specific bioinspired features was collected for a sample of bioinspired designs, as

was information on the standard features in non-bioinspired designs. For instance, the

bioinspired passive cooling system of Eastgate Centre, a shopping center in Zimbabwe, was

compared to that of a traditional electric air conditioner for a similarly-sized building using the

DfE guidelines. It was found that the passive cooling system met four of the guidelines better

than the competing product as a result of its bioinspired features. The results from analyzing the

nine bioinspired designs together showed that many of the environmental differences between

the bioinspired and non-bioinspired designs were related to a small subset of the DfE guidelines,

allowing for the identification of trends in the types of environmental advantages that have been

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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achieved using biological analogies. Because practical considerations prevented the collection of

sufficient information to conduct LCAs for all eighteen designs analyzed in the study by

O’Rourke and Seepersad [81], the conceptual differences between bioinspired designs and their

competitors were compared using the DfE guidelines.

An advantage of using DfE guidelines for this purpose is that the guidelines offer breadth and

detail. They cover all life cycle phases of a product, with a level of detail that still allows nuances

in energy efficient solutions, for instance, to become apparent. Without time to accurately

conduct LCAs, guidelines facilitate environmental comparisons between designs at a conceptual

level. Midzic et al.[82] found that designers who use guidelines to rate product concepts are

more consistent than designers who do not have guidelines.

A disadvantage of this approach is that it lacks quantitative measures for the relative

environmental impact of products, with weights for the importance of different types of impacts.

For instance, this approach might show that design A is better than design B for guideline #1, and

that B is better than A for guideline #2; but it will not indicate which of the two alternatives has a

lower environmental impact overall. If one uses the guidelines to assess the sustainability of

designs, it may be helpful to use content beyond the guideline list to ensure that all researchers

are interpreting the guidelines the same way.

6. CLOSURE

A total of 6 DfE strategies and 76 DfE guidelines were reconciled from 20 sources, and a

subset was illustrated with examples. The guidelines are intended to be used in the early stages

of design to reduce environmental impacts of products and systems. The guidelines can be used

as prompts for ideation, as expert knowledge in automated design guidance, and as criteria for
Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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evaluating early stage design alternatives. Industrial application and utilization of these

guidelines may differ, and Pigosso et al. [44] provide an Eco-Design Maturity Model to help

managers set appropriate goals for their design teams. The guidelines presented here are intended

to serve as the foundation for a comprehensive and expandable database of DfE guidelines;

future work may include continued validation, documentation, and systematic development of

this foundation. Since DfE guidelines are continually evolving [54,83], it is possible that

researchers could create a digital database for submitting and updating guidelines. Also in future

work, it would be interesting to examine conflicts between guidelines more thoroughly. Brezet et

al. [42] present a table of the conflicts and complements between DfE strategies and other design

considerations (e.g. safety and cost). One readily available example is the conflict between

enabling repair and upgrading and eliminating the need for replacements with a more durable

innovation. A solution to this conflict could involve modular upgradeability, as in the example of

modern computers.

ACKNOWLEDGMENTS

Cassandra Telenko was supported by an NSF Graduate Research Fellowship, and Julia

O’Rourke was supported by an NSF Graduate Research Fellowship and a Powers Fellowship

from the University of Texas at Austin. We also gratefully acknowledge the members of the

Webber Energy Group and the Product, Process, and Materials Design Lab at the University of

Texas at Austin.

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Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

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Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404,

Page 42
Table of Figures

Figure 1: The Product Development Stages, Showing LCA as a Retrospective Tool and DfE Guidelines
as a Concurrent Design Tool [15]
Figure 2: Final DfE Mind Map (abridged)
Figure 3: Xerox® Uses Remanufactured Modules (Adapted from [59,60])
Figure 4: Wearer’s Movement Powers the Seiko Kinetic® Auto Relay [65]
Figure 5: The Black and Decker® Leaf Hog™ Uses a Ribbed Structure to Increase Strength and Reduce
Material Use
Figure 6: Bitters Company Uses the Original Coloring and Low Density of Flip Flop Scraps to Make
Products such as Floating Keychains and Doormats [65]
Figure 7: SinkPositive Diverts Tank Water Through a Faucet [40]
Figure 8: The ECO kettle™ Responds to User Habits and Helps Users Heat Only What They Need [66]
Figure 9: The IKEA POANG Chair has been Successful Since 1977 [69]
Figure 10: Ford Model U Concept Car has a Modular and Upgradeable Interior [71]

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404, Page 43


Table of Tables

Table 1: DfE Guidelines

Corresponding Author: Cassandra Telenko, Cassandra.telenko@me.gatech.edu, Paper: MD-15-1404, Page 44

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