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Sustainable Design and Manufacturing Strategies

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A special issue of Sustainability (ISSN 2071-1050). This special issue belongs to the section "Sustainable Materials".

Deadline for manuscript submissions: closed (31 March 2024) | Viewed by 8252

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Special Issue Editors

Prof. Dr. Carlos Vila-Pastor

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Guest Editor

Department of Mechanical and Materials Engineering, Polytechnic University of Valencia, 46022 Valencia, Spain
Interests: design for manufacturing and assembly; green manufacturing; advanced manufacturing techniques; additive manufacturing; high-speed machining; collaborative engineering; digital manufacturing; sustainability indicators; processes modelling; continuous improvement product lifecycle management
Special Issues, Collections and Topics in MDPI journals

Dr. Jose Vicente Abellan-Nebot

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Guest Editor

Department of Industrial Systems Engineering and Design, Universitat Jaume I, Avinguda de Vicent Sos Baynat, s/n, 12071 Castelló de la Plana, Castelló, Spain
Interests: intelligent machining; multistage manufacturing processes; quality control; design for manufacturing and assembly sustainable machining; green manufacturing; advanced manufacturing techniques; additive manufacturing; high-speed machining
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The worldwide awareness of our environmental future has pushed international organizations and countries towards encouraging ecological preservation actions through laws, directives and initiatives. In 2015, the United Nations established the seventeen-point Sustainable Development Goals call for action for 2030 to guarantee resources from economic, social and environmental points of view. Two of these goals are related to industries, production and innovation. However, sustainable industrial design and development are some of the main issues for manufacturing companies when it comes to addressing the natural resource limitations and pollution problem.

Individual responses are needed, comprising a broad vision of all activities involved in the entire product’s lifecycle. Therefore, we believe that sustainable design and manufacturing practices could help with the innovation of cleaner production pertaining to products and processes.

Consequently, the objective of this Special Issue is to publish the latest high-quality works in research, development and innovation in design and manufacturing activities. We are very interested in contributions investigating improvements in green product design and manufacturing processes, focusing on one activity or transversal procedures.

Moreover, we encourage the submission of papers with the potential to help compile all key knowledge in sustainable product lifecycle strategies.

This Special Issue covers, but is not limited to, the following topics:

Design for sustainable manufacturing;
Design for the environment;
Green manufacturing;
Advanced green manufacturing technologies;
Digital manufacturing;
Product end-of-life and remanufacturing;
Innovative process planning;
Metrics for sustainable production;
Concurrent engineering;
Collaborative manufacturing;
Industry 4.0;
Quality assurance.

Prof. Dr. Carlos Vila-Pastor
Dr. Jose Vicente Abellan-Nebot
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Sustainability is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

design for sustainable manufacturing
design for the environment
green manufacturing
advanced green manufacturing technologies
digital manufacturing
product end-of-life and remanufacturing
innovative process planning
metrics for sustainable production
concurrent engineering
collaborative manufacturing
Industry 4.0
quality assurance

Published Papers (6 papers)

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Research

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19 pages, 1848 KiB

Open AccessArticle

Bio-Based Plastics in Product Design: The State of the Art and Challenges to Overcome

by Puck Bos, Linda Ritzen, Sonja van Dam, Ruud Balkenende and Conny Bakker

Sustainability 2024, 16(8), 3295; https://doi.org/10.3390/su16083295 - 15 Apr 2024

Viewed by 731

Abstract

Replacing fossil-based feedstock with renewable alternatives is a crucial step towards a circular economy. The bio-based plastics currently on the market are predominantly used in single-use applications, with remarkably limited uptake in durable products. This study explores the current state of the art of bio-based plastic use in durable consumer products and the opportunities and barriers encountered by product developers in adopting these materials. A design analysis of 60 durable products containing bio-based plastics, and 12 company interviews, identified the pursuit of sustainability goals and targets as the primary driver for adopting bio-based plastics, despite uncertainties regarding their reduced environmental impact. The lack of knowledge of bio-based plastics and their properties contributes to the slow adoption of these materials. Furthermore, the lack of recycling infrastructure, the limited availability of the plastics, and higher costs compared to fossil-based alternatives, are significant barriers to adoption. Product developers face significant challenges in designing with bio-based plastics, but opportunities exist; for example, for the use of dedicated bio-based plastics with unique properties. When designing with bio-based plastics, product developers must think beyond the physical product and consider sourcing and recovery, which are not typically part of the conventional product design process. Full article

(This article belongs to the Special Issue Sustainable Design and Manufacturing Strategies)

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38 pages, 1129 KiB

Open AccessArticle

Designing Sustainability Today: An Analytical Framework for a Design for Sustainability Model in European Fashion and Furniture Industries

by Erminia D’Itria, Xue Pei and Paola Bertola

Sustainability 2024, 16(8), 3240; https://doi.org/10.3390/su16083240 - 12 Apr 2024

Viewed by 608

Abstract

The proposed article addresses pressing sustainability challenges, advocating for a profound transformation of existing development models, particularly emphasizing sustainable production and lifestyles. Utilizing a research method grounded in a comprehensive international knowledge base, the study explores the evolution of design for sustainability (DfS) approaches. Its significant contribution lies in systematically investigating connections among diverse DfS approaches, providing an initial framework for situating practices within the fashion and furniture industries. The research outcomes obtained iteratively involve mapping design-driven sustainability practices in European fashion and furniture companies. This mapping reveals a transition from a product-centric to an organization-centered design perspective, calling for a holistic ecosystemic framework to revolutionize business operations. The article analyzes contemporary design-driven practices, proposing an interpretative model that identifies ongoing practices fostering incremental changes toward sustainability guided by design. Furthermore, the article outlines a three-stage design-driven sustainability continuum, synthesizing potential future trajectories. Beyond contributing to the understanding of current practices, the research provides insights into future possibilities, highlighting the transformative role of design in reshaping consumeristic systems. Ultimately, the study offers valuable insights into the transformative power of design, paving the way for sustainable business practices in the fashion and furniture industries. Full article

(This article belongs to the Special Issue Sustainable Design and Manufacturing Strategies)

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17 pages, 1081 KiB

Open AccessArticle

Remanufacturing Assessment of Machine Tools under a Circular Economy Perspective: A Resource Conservation Initiative

by Plinio Centoamore and Luiz Fernando Rodrigues Pinto

Sustainability 2024, 16(8), 3109; https://doi.org/10.3390/su16083109 - 9 Apr 2024

Viewed by 546

Abstract

Machine tools are recognized as goods-generating equipment that constitute the realm of manufacturing facilities, providing the means of production for the generation of consumer products. This work explores the possibility of implementing sustainability concepts, employing criteria from a circular economy in the design and manufacturing of new equipment, using existing structural elements as the basis for the development of these machines. Stamping presses for automotive body panels were considered as the focus of this study. A quantitative evaluation of the possibilities for reusing existing components was developed using an algebraic tool, through the creation of algorithms that facilitate the comparative analysis of production costs and delivery lead times. Additionally, a case study was conducted to assess the capability of these algorithms to provide results, presented as comparative indicators that should be taken into consideration and may assist in the decision-making process regarding the implementation or not of the possibilities presented by the study. The simulation performed proved to be proficient, providing data that can guide decision making regarding the reuse of the chosen structural elements, based on their soundness verified through inspections conducted by the machine designers. Full article

(This article belongs to the Special Issue Sustainable Design and Manufacturing Strategies)

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22 pages, 5866 KiB

Open AccessArticle

Cleaner Chips: Decarbonization in Semiconductor Manufacturing

by Prashant Nagapurkar, Paulomi Nandy and Sachin Nimbalkar

Sustainability 2024, 16(1), 218; https://doi.org/10.3390/su16010218 - 26 Dec 2023

Viewed by 2149

Abstract

The growth of the information and communication technology sector has vastly accelerated in recent decades because of advancements in digitalization and Artificial Intelligence (AI). Scope 1, 2, and 3 greenhouse gas emissions data of the top six semiconductor manufacturing companies (Samsung Electronics, Taiwan Semiconductor Manufacturing Corporation, Micron, SK Hynix, Kioxia, and Intel) were gathered from the publicly accessible Carbon Disclosure Project’s (CDP) website for 2020. Scope 3 emissions had the largest share in total annual emissions with an average share of 52%, followed by Scope 2 (32%) and Scope 1 (16%). Because of the absence of a standardized methodology for Scope 3 emissions estimation, each company used different methodologies that resulted in differences in emissions values. An analysis of the CDP reporting data did not reveal information on strategies implemented by companies to reduce Scope 3 emissions. The use of renewable energy certificates had the largest effect on decarbonization centered on reducing Scope 2 emissions, followed by the deployment of perfluorocarbon reduction technologies to help reduce Scope 1 fugitive emissions. Technology-specific marginal abatement costs of CO₂ were also estimated and varied between −416 and 12,215 USD/t CO₂ eq., which primarily varied depending on the technology deployed. Full article

(This article belongs to the Special Issue Sustainable Design and Manufacturing Strategies)

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20 pages, 4375 KiB

Open AccessArticle

An Eco-Innovative Green Design Method using the Theory of Inventive Problem Solving and Importance–Performance Analysis Tools—A Case Study of Marker Pen Manufacturing

by Kai-Chao Yao, Shu-Hua Huang, Kuo-Yi Li, Hsiu-Chu Hung, Jing-Ran Xu, Wei-Lun Huang, Wei-Sho Ho, Jiunn-Shiou Fang and Ying-Ju Tseng

Sustainability 2023, 15(19), 14414; https://doi.org/10.3390/su151914414 - 1 Oct 2023

Viewed by 2139

Abstract

This study explores innovative designs for the cap of a marker pen, aiming to address the issues of cap loss and ink evaporation during marker pen usage. This study applies intrinsic safety, universal design and TRIZ as research methods. TRIZ has great potential to address most of the Sustainable Development Goals (SDGs) relevant to conflict-oriented problem solving for innovations. The principles of simplification, foolproof design, clarity of states, and tolerance from intrinsic safety were applied to prevent cap loss and minimize the risks associated with ink evaporation. The TRIZ methodology’s contradiction matrix was utilized to identify relevant inventive principles by improving parameters and avoiding worsening parameters, providing a reference basis for product structure design. Lastly, the principles of equitable use, simplicity, intuitiveness, and effortless design from universal design were employed to enhance the marker pen’s usability for the general public. This study creates a SERVQUAL questionnaire to compare the prototype of the designed pen cap with commercially available pen caps. It utilizes the two-dimensional quality model (Kano model) and Importance–Performance Analysis (IPA) for practical design analysis. Finally, the prototype structure is visualized using graphic software. The innovative design features of this study include the following. (1) Concealable pen tip: the sliding seal hides the pen tip inside the pen body when the pen core is slid upwards, preventing cap loss and ink drying. (2) Quick retractable function: using a pressing mechanism, the pen tip can be quickly retracted with a one-handed press and slide motion. (3) Replaceable pen core: the pen core can be replaced by disassembling the pen body, removing the old pen core, and inserting a new one, thereby extending the pen’s lifespan. (4) Satisfaction evaluation of the innovative pen cap design: through questionnaire surveys and cross-analysis using the IPA and the Kano model, this study assesses the product’s manufacturing and mass production value to reduce actual product development costs and time. Full article

(This article belongs to the Special Issue Sustainable Design and Manufacturing Strategies)

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Review

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33 pages, 6520 KiB

Open AccessReview

A Review of the Factors Influencing Surface Roughness in Machining and Their Impact on Sustainability

by José V. Abellán-Nebot, Carlos Vila Pastor and Hector R. Siller

Sustainability 2024, 16(5), 1917; https://doi.org/10.3390/su16051917 - 26 Feb 2024

Viewed by 1234

Abstract

Understanding surface roughness generation in machining is critical to estimate the final quality of the part, optimize cutting conditions, reduce costs and improve manufacturing sustainability in industry. This work presents a review of the factors that affect surface roughness generation in machining (turning/milling) processes. Up to twenty-five different factors were identified, which were classified as setup factors (cutting tool, machine tool/fixturing and workpiece factors), operational factors (cutting and process parameters) and processing factors, which are related to the resulting cutting processes, such as built-up edge, chatter or tool wear. The importance of understanding these factors to improve machining sustainability is highlighted through three case studies, ranging from a simple change in the cutting insert to a more complex case where a controlled surface roughness leads to the elimination of a grinding stage. A case study illustrating the potential benefit of MQL in the sustainability of the machining process is also reported from the mold manufacturing industry. In all of the cases, the improvement in sustainability in terms of the reduction in kg of CO₂ equivalent is notable, especially when grinding operations are reduced or eliminated from the manufacturing process. This paper can be of interest to practitioners in finishing operations at milling and turning operations that want to increase machining sustainability through a deep understanding of surface roughness generation. Full article

(This article belongs to the Special Issue Sustainable Design and Manufacturing Strategies)

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