Structural optimization strategies to design green products

• A method for ECO design integrated in CAD/CAE environment is proposed.
• Structural optimization tool and a comprehensive LCA (life cycle assessment) tool have been combined for the first time to make the designer aware of how his/her design choices affect the whole product life cycle.
• Structural optimization strategies can be set for generating multi-objectives optimization (shape/material/production process) complying with both functional and environmental requirements.
• An industrial case study has been developed to validate and demonstrate the efficacy of the new method.

This paper addresses the need for a structured approach to environmental assessment and improvement. We propose a computer-aided methodology, named Eco-OptiCAD, based on the integration of Structural Optimization and Life Cycle Assessment (LCA) tools. Eco-OptiCAD supports the designer during product development, highlighting when and where the core of the environmental impact lies. Furthermore, it provides effective tools to address such impacts, improving the original product, while ensuring structural and functional requirements. It foresees the synergic use of (1) virtual prototyping tools, such as 3D CAD, Finite Element Analysis (FEA) and Structural optimization, (2) function modeling methodology and (3) Life Cycle Assessment (LCA) tools. The kernel of the methodology is constituted by a set of optimization strategies and a module, named Life Cycle Mapping (LCM). In particular, we have conceived ten optimization strategies converting environmental objectives and constraints into structural and geometrical parameters. They enable the designer to generate alternative green scenarios according to the triad shape–material–production. The LCM tool has been specifically developed to easily trace the growth of environmental impacts throughout the product's life cycle and allow the user to focus his effort on the most relevant aspects. Thanks to the integration of the structural optimizer with an LCA map, the designer becomes aware of the consequences that each change in the geometry, the material or the manufacturing process will produce on the environmental impact of the product throughout its life cycle. With a complete view of the product life cycle, the designer can improve a single phase, while retaining a global perspective; thus avoiding the possibility of gaining a local green improvement at the cost of a global increase in environmental impacts.An exemplary case study is presented to detail each step of the design methodology and shows its potential. Eco-OptiCAD represents a first step toward a fully integrated system for eco-design assessment and improvement, with the potential of working side by side with common design tools, in providing a constant environmental feedback.