Can Product Design Contribute to Sustainable Manufacturing? We Find Out.
Driven by customer demands and regulatory pressures, the global focus on sustainability has shifted from ambition to action over the course of a few decades.
The concept gained considerable public traction with the Brundtland Commission Report of 1987, which popularised sustainable development as “meeting the needs of the present without compromising the ability of future generations to meet their own needs.” The Millennium Development Goals (MDGs) and Sustainable Development Goals (SDGs) further embedded these principles in the public consciousness.
But in the early years, sustainability was often seen as an ideal — desirable but distant, something to be addressed in the 'future.' It was considered secondary to immediate economic and developmental concerns.
That ‘future’ is now upon us. Sustainability is recognised as a business imperative today, with organisations increasingly recognising that sustainable practices are crucial not only for the environment but also for their long-term success and resilience, driven by both regulatory pressures and customer expectations.
Evidence supports this shift: 87% of ‘senior decision makers’ surveyed in the 2023 Sustainability in Manufacturing report indicated that sustainability is becoming more important within their organisations. Additionally, approximately 75% of respondents of the Deloitte 2023 CxO Sustainability Report reported that their organisations have increased sustainability investments over the past year, with nearly 20% indicating a significant increase. What once seemed like a distant aspiration is now a critical, non-negotiable priority for businesses worldwide.
However, it's important to acknowledge that sustainability is a complex subject with ongoing challenges. The first survey revealed that while many companies recognise its importance, they struggle to develop effective strategies to improve the sustainability of their operations, with three out of 10 reporting significant obstacles in this area.
As seasoned professionals in product design and tactile sensing technology, who work closely with manufacturers to bring our products to life, we’ve gained valuable insights into navigating the complexities of sustainability in manufacturing. Our experiences have taught us that achieving sustainability in this process is a complex journey requiring patience, dedication, innovation, and adaptability. We are committed to continually advancing our sustainability efforts as part of an ongoing process.
In this blog, we will explore how product design can contribute to a more sustainable future. We'll also share strategies, lessons learned, inspiring case studies, and the challenges we've encountered along the way. Our hope is to motivate others who are also navigating the complexities of sustainability in product design and manufacturing, particularly in the tactile sensing technology space.
What exactly is sustainability and sustainable manufacturing?
One of the primary challenges in a business’s journey toward sustainability is the lack of a universally accepted definition. This ambiguity complicates efforts to consistently implement and measure sustainable practices. Acquainting ourselves with widely recognised definitions can help provide clarity. Below are two definitions of ‘sustainability’ and ‘sustainable manufacturing’:
“Sustainability is about meeting the world’s needs of today and tomorrow by creating systems that allow us to live well and within the limits of our planet.”
“Sustainable manufacturing is the creation of manufactured products through economically-sound processes that minimise negative environmental impacts while conserving energy and natural resources. Sustainable manufacturing also enhances employee, community and product safety.”
– United States Environmental Protection Agency
Sustainability is a broad and evolving concept. Is it merely about reducing one's carbon footprint, or does it also involve resource efficiency – minimising waste, using less material, and optimising resource use? Perhaps it includes embracing a circular economy – designing products for longer life cycles, promoting reuse and recycling, and reducing reliance on virgin materials. It could also encompass social responsibility, such as ensuring fair labour practices, safe working conditions, and contributing to local communities. Additionally, sustainability may involve managing supply chains ethically and reducing environmental impacts across the entire production process.
Sustainability may encompass some or all of these elements, and the context in which they are applied is crucial.
In product design and development, the Triple Bottom Line (TBL) framework provides a comprehensive approach to defining sustainability. TBL encourages companies to evaluate their social and environmental impacts alongside their financial performance, a departure from focusing solely on profit, the traditional 'bottom line’.
Using this framework, we might define sustainability in product design and manufacturing as:
“The process of creating products that address environmental, social, and economic impacts. This includes utilising recyclable or bio-based materials, designing for durability and ease of repair, and minimising energy consumption and waste throughout the manufacturing process. The aim is to mitigate environmental impact, promote social well-being, and ensure economic viability.”
However, putting this into practice is challenging. The manufacturing value chain – from engineering and design to sourcing, production, transportation, and disposal – is complex, with many factors beyond our direct control.
Product designers often have limited control over supply chain sustainability and disposal. In the Sustainability in Manufacturing report, 54% of respondents cited this as a key challenge, while 40% struggled to scale sustainability initiatives, despite success in smaller projects.
Despite these challenges, at TG0, we focus on what we can control. We concentrate on strategies and actions where our technology and methods can advance sustainability, always aiming to expand that impact
The importance of our role as product designers.
Over the years, various figures have underscored the critical role of product design in shaping environmental impact. One widely cited statistic, suggests that 80% of a product's environmental impact is determined by decisions made during the design stage. (Some researchers have, however, pointed out that the exact source of this figure remains unclear.)
The Boston Consulting Group, meanwhile, has noted that “in its experience” companies can reduce a product’s environmental impact by up to 40% by using conventional design technologies.
Even if we consider the lower figure of 40%, it’s clear that thoughtful design choices hold significant potential for reducing a product’s environmental footprint. And this is where we come in.
3 things we can do right now.
While full sustainability is a long-term goal, certain steps in sustainable manufacturing can be implemented more quickly than others. Immediate actions like reducing the bill of materials (BOM) and optimising material usage can have a significant impact right away. Here’s what we can do right now:
1. Reduce the BOM
Reducing the complexity of the Bill of Materials (BOM) at the product design stage offers several interrelated benefits, particularly in terms of sustainability, durability, and cost efficiency:
- Cost reduction and resource efficiency: Simplifying the BOM lowers production costs by minimising material expenses and streamlining the assembly process. Fewer components reduce waste and enhance resource and energy efficiency during production, aligning with sustainability goals.
- Enhanced durability and resilience: A streamlined design minimises potential points of failure, thereby extending product longevity. By investing in higher-quality materials for the remaining parts, durability is further improved. Additionally, fewer components result in less wear and tear over time, making the product more resilient and contributing to its overall sustainability.
- Improved assembly efficiency: With a reduced BOM, the assembly process becomes more straightforward, reducing the risk of errors and optimising resource use. This efficiency supports a more green manufacturing process by lowering energy consumption and material waste.
In the automotive industry, Tesla provides a compelling example of reducing BOM complexity by integrating multiple components into fewer, multifunctional parts, simplifying the production of its electric vehicle (EV) components.
At TG0, our technology integrates the production of the aspect material with our patented sensors, minimising the number of parts and materials needed to embed sensing capabilities. This approach reduces manufacturing waste, energy consumption, and reliance on electronic components, while also lowering the need for rare earth metals. Additionally, it provides lightweight opportunities and enhances durability through seamless, ingress-free surfaces.
We recognise this is just the beginning. And we are constantly innovating and actively exploring new ways to further improve efficiency and sustainability in our processes.
2. Material usage: Reduce, reuse, recycle, repeat
E-waste is the fastest-growing solid waste stream globally — with 53.6 million tonnes produced in 2019, of which only 17.4% was formally collected and recycled. Furthermore, the extraction and processing of primary raw materials account for half of global greenhouse gas (GHG) emissions and 90% of biodiversity loss.
These figures highlight the essential role of material selection in mitigating environmental impact, especially in industries that heavily depend on plastics, including consumer electronics, automotive, medical devices, and home appliances.
Some companies are already addressing this by replacing raw materials with more sustainable or bio-based alternatives and selecting materials that are easier to recycle or reuse at the product design level.
In the aviation industry, for instance, Airbus is exploring alternatives to traditional fossil-fuel-based carbon fibres used in aircraft components like fuselage shells and wings. The company has developed an experimental helicopter panel using bio-derived fibres that was flight-tested in May 2024 to demonstrate its airworthiness.
Similarly, the plastics industry is making strides by incorporating more Post-Consumer Recycled (PCR) resin and opting for recycled, renewable, recyclable, bio-based, or biodegradable materials instead of traditional carbon-intensive options. As part of their attempts to be more sustainable, many businesses are also choosing to not use finishes such as films and sprays that contaminate waste streams.
The automotive industry has been researching and developing alternative materials for plastic components too. South Korean multinational Hyundai, for instance, has incorporated sustainable materials throughout the design of its IONIQ 5. The EV’s seat fabric is crafted from recycled PET bottles, while the headlining and carpet fabric are made using bio-based materials derived from sugarcane and corn. The leather interiors are dyed with flaxseed oil, and the door detailing features 100% recyclable paperette. Additionally, the doors and crash pads are finished with eco-friendly bio paint.
A 2023 Deloitte survey found that 59% of companies have begun using sustainable materials, such as recycled or lower-emitting products. But there are challenges here too. 44% of respondents said ensuring that suppliers and partners meet specific sustainability criteria was a challenge, highlighting the complexities of implementing these practices across the supply chain.
Circular design
Adopting a circular design approach is another effective way to use fewer materials and enhance sustainability. This approach emphasises creating products that can be reused, repaired, remanufactured, or recycled, aiming to minimise waste and reduce the demand for new raw materials.
Earlier this year, luxury consumer electronics company Bang & Olufsen presented a compelling example of circular design when it launched the Beosystem 9000c that it created by buying back 200 units of its iconic Beosound 9000 CD player from the 1990s, and remanufacturing and upgrading them with modern technology in its factory. By sourcing and restoring original components and integrating them with the latest audio innovations, B&O demonstrated that high-quality products can be given a second life, reducing waste. Although the original design did not anticipate this refit, this experiment underscores the potential for products to be refitted to meet contemporary standards of design and sustainability.
“...[W]e are showcasing how Bang & Olufsen’s unique capabilities within sound, design and craftsmanship are creating long-lasting, circular products. We want to demonstrate that a second-life product can be just as attractive as a new product and that a high-quality item such as the Beosound 9000 doesn’t need to have an end date,” Mads Kogsgaard Hansen of Bang & Olufsen told Forbes.
A fine balance
Balancing sustainability with other critical factors, such as cost, performance, and regulatory requirements, is also an important consideration. In the context of touch-sensing technology, this might involve selecting materials that meet both sustainability criteria and the high-performance standards required for sensitive electronic components. In some cases, it might be more sustainable to use certain types of plastic over bio-plastic due to certification or safety requirements, while ensuring the material can still be recycled effectively.
Finally, sustainability extends beyond just choosing sustainable materials; it also involves paying attention to how these materials are combined. Different materials are recycled and processed differently, so reducing the variety of materials in a product can simplify disassembly and recycling, making the disposal process more environmentally friendly.
At TG0, as product integration and streamlined manufacturing trends evolve, our researchers are investigating reversible joining methods for double-shot injections and reversible bonding/welding processes to facilitate the easy separation of different materials.
3. Modular design for the win
In the quest for sustainable manufacturing, modular design stands out as a key innovation. It involves structuring products into interchangeable, independent units that connect through defined interfaces, similar to how Lego pieces fit together.
Modular design significantly enhances a product's flexibility, repairability, and upgradeability by allowing individual components to be replaced or upgraded independently. This not only extends the product's lifecycle but also reduces electronic waste, conserves resources, and supports a circular economy by prioritising repair and refurbishment over complete disposal.
However, experts have pointed out that user behaviour significantly influences a product's overall environmental impact and the environmental benefits of modular design can be limited in markets where consumers prefer brand-new products.
A good example of modular design is the Framework Laptop that is designed to be easily repaired and upgraded. Introduced in 2021, each component of this laptop is easily removable, and all components and slots are labelled with names and QR codes that direct users to an affordable spare parts page.
Beyond its environmental advantages, modular design offers economic benefits for both consumers and product designers. Consumers save money by upgrading parts rather than purchasing entire new products, while product designers can generate revenue from selling upgrade modules and repair services. This approach also optimises material use, reduces the need for excessive inventory, and can provide tailored solutions across various industries, including electronics, furniture, automotive, and fashion.
By embracing modularity, companies can develop more sustainable products that adapt to evolving needs, contributing to a more resource-efficient and environmentally responsible market.
At TG0, our products integrate electronic hardware with polymer components to ensure a stable and resilient connection between our polymer-based sensors and the printed circuit board (PCB). We prioritise using reversible connectors to facilitate disassembly and minimise the variety of connectors within a single product.
Our eteeController for SteamVR is a great example of modularity. The main body of the controller consists of two interlocking parts that fit together without the need for fasteners. The sensor is wrapped around this assembly. Once assembled, the PCB with electrical connections slides into place, creating a stable connection with the sensing materials through friction, eliminating the need for additional connectors. Finally, an outer skin is assembled on top, and the handle is attached. This design allows all parts, made from different materials, to be easily assembled and disassembled.
CTA: Read more: Modular products: all you need-to know
- Innovate, innovate, innovate
“We grew up in a world dominated by the linear economy, and now we need to shift to a circular economy. That requires a completely different mindset. Everything we do must be questioned.”
– Dr Caroline Cassignol, Siemens, in Rethink: Why sustainable product design is the need of the hour
As we create and innovate, it's essential to keep reminding ourselves that longstanding design approaches for products may no longer be the most effective. Advances in technology, new materials, and evolving processes mean that what once required numerous components can now be streamlined significantly, often with more sustainable materials.
Innovation provides companies with a competitive edge, and first movers are likely to reap the greatest benefits, say experts.
“As disruptive forces continue to change operational realities across manufacturing sectors, companies looking to achieve competitive advantage may need to allocate more resources towards product innovation,” noted a 2021 Deloitte report. “Those prepared to act quickly could stand to benefit the most. After all, product reinvention requires that proper scientific and technical underpinnings be in place in advance. The manufacturers farthest along this path could conceivably become the next ‘big’ sustainable brands in 5 to 10 years’ time.”
Embracing innovation in product design requires a thorough reassessment of the entire process, with a shift toward systems thinking and circular design. By evaluating a product's lifecycle holistically – from initial design to end-of-life – businesses can enhance their sustainability efforts by incorporating disassembly, longevity, reusability, and modularity from the outset. This approach ensures that sustainability is considered at every stage, leading to products that are more environmentally responsible. Adopting this forward-thinking strategy not only drives innovation but also reinforces a commitment to sustainability throughout the product's lifecycle.
Despite the importance of a systems-thinking approach in product design, only 12% of organisations have adopted it, according to a 2022 report by the Capgemini Research Institute. Those willing to embrace this approach face challenges as well. Many organisations lack the technological capabilities needed to support systems thinking, with nearly 48% identifying a shortage of skilled talent in sustainable product design as a major obstacle to achieving sustainability. The report also reveals that only 30% of organisations believe they have adequate systems-thinking skills within their product design teams, and only 37% report having sufficient expertise in circular design approaches.
“Organisations also lack fundamental sustainable design skill sets, such as systems thinking and circular design thinking,” said the report. “Further, while technologies such as Life Cycle Assessment (LCA) tools, artificial intelligence/machine learning (AI/ML), additive manufacturing, bio-innovation, and digital twins can significantly aid sustainable product design, most organisations do not have adequate capabilities in these areas.”
But there are ways around that too.
At TG0, we provide the systems-thinking expertise necessary to drive innovation in product design and manufacturing, enabling companies to implement sustainable practices without in-house capabilities. We offer practical and structured solutions for companies with limited resources, including targeted innovation workshops that capture and refine product ideas. These ideas are then developed into feasible, manufacturable solutions using our advanced technology platform.
Finally, data collection through data-enabled surfaces is another area that propels innovation and enhances sustainability. By embedding efficient, low-cost sensing in product surfaces, companies can gather valuable data on pressure, twist, torque, and vibration. This data can be used to optimise product performance and longevity, leading to fewer replacements and reduced waste. Additionally, improved insights into product usage can drive more sustainable design decisions, helping to create products that are not only more aligned with customer needs but also more resource-efficient throughout their lifecycle.
This brings us to the common challenges encountered on the path to sustainability.
Common Challenges
Cost
Incorporating sustainable practices into product development is often perceived as cost-intensive due to factors like higher initial investments, R&D expenses, supply chain adjustments, and certification and compliance costs.
However, experts posit that the long-term benefits of sustainable design far outweigh these upfront costs. As new technologies and materials are tested, adopted, and scaled, sustainable product development can ultimately lead to substantial cost savings.
Research from Deloitte underscores this potential, revealing that while climate inaction could cost the global economy $178 trillion over the next 50 years, a swift transition to net-zero could generate $43 trillion in gains during the same period. Research also found that 23% of organisations have experienced reduced costs due to adopting sustainable design strategies, while 37% reported no change in costs. Notably, even among those who saw cost increases, 51% found that the benefits gained from sustainability outweighed the additional expenses. Furthermore, customers are also responding positively to efforts by organisations to become more sustainable, with 70% of organisations in the Capgemini report reporting higher customer satisfaction levels as a direct result of their sustainable product design initiatives.
This highlights that sustainable design can indeed lead to long-term financial benefits stemming from reduced resource consumption, lower waste management costs, and enhanced market appeal.
At TG0, we understand that integrating sustainability into product development involves a balanced approach to cost and innovation. By focusing on practical solutions like reducing the BOM complexity and incorporating advanced material technologies, we help companies achieve sustainability goals while managing costs effectively.
While cost remains a significant challenge, it is not the only one. Organisations must also navigate a range of external and internal challenges such as lack of easily available sustainable materials, lack of coordination between product designers and external stakeholders such as suppliers, contract manufacturers and so on. Notably, 54% of organisations identify the lack of data on the environmental and social impacts of products as a key challenge to designing sustainable products. And this brings us to Life Cycle Assements or LCAs.
Life Cycle Assessments (LCAs)
Conducting LCAs is crucial for understanding and minimising the environmental and social impacts of a product throughout its lifecycle, from raw material extraction to final disposal. LCAs offer insights into how various stages of the value chain contribute to these impacts, enabling companies to make informed decisions to reduce them and enhance overall circularity.
Despite its clear benefits, many organisations struggle with implementing LCAs. An estimate shows that only about one-quarter of organisations regularly conduct environmental or social impact assessments as part of their product design process, with only 8% performing both consistently. A PwC analysis of LCAs found that 69% of companies have performed LCAs on less than 25% of their product lineups.
For small and medium-sized companies, the complexity and data requirements of LCAs are particularly daunting, often due to limited resources and expertise.
However, as customer demands and sustainable supply chain decisions drive rapid adoption, more companies are recognizing the importance of LCAs in their strategic planning.
At TG0, we acknowledge these challenges and are exploring ways to integrate LCAs into our processes and support our customers in doing so too. Our goal is to make this essential practice more accessible and manageable, ensuring that even companies with limited resources can benefit from the insights LCAs provide.
Conclusion
Whether you're a small enterprise or a global corporation, it's essential to recognise that sustainability is an incremental and long-term process. It’s not about achieving a single, monumental milestone but rather making a series of continuous improvements. Thoughtful changes in materials, green manufacturing techniques, and lifecycle management during product design can gradually reduce a component or product’s environmental impact.
Taking a long-term perspective is crucial. While upfront costs may be a concern, considering the total cost of ownership — including maintenance and operational expenses for your customers — can reveal the true value of sustainable practices.
Philips, a global leader in health technology, provides a compelling example of a product design-led innovation that has helped its customers save thousands of dollars a year while also contributing to sustainability. Its innovative BlueSeal magnet, used in magnetic resonance imaging (MRI) systems, requires just seven litres of liquid helium for cooling, instead of the 1,500 litres that conventional magnets use. Given that helium is a finite, non-renewable and expensive resource, this innovation not only reduces operational costs for its customers but also significantly decreases the environmental impact associated with helium extraction and consumption.
Evaluating the holistic impacts of sustainability – environmental, social, and financial – can guide better decision-making. As we’ve discussed earlier, sustainability is not just responsible; it's also advantageous for business. By assessing the risks of unsustainable alternatives and exploring opportunities for innovation and differentiation, companies can turn sustainability into a competitive advantage.
Engaging with industry partners and stakeholders in a collaborative approach amplifies the impact of sustainable initiatives, enabling the sharing of knowledge and resources. Ultimately, adopting sustainable practices is not just about safeguarding the environment – it’s about building a resilient and prosperous future for businesses and communities alike.
If you're looking for a collaborative partner to help you along your sustainable manufacturing journey, click here and let's chat.
