DFE : Design For Environment

Introduction

Design for Environment (DFE) is an approach that focuses on minimizing a product's environmental impact throughout its entire lifecycle, from the concept phase to disposal. It aims to create environmentally friendly, sustainable, and efficient products. DFE is a crucial aspect of the broader Design for Excellence (DFX) philosophy, which includes various design methodologies to improve product quality, reliability, and overall performance.

Ecodesign

Designers may encounter the term ecodesign. The ISO 14006:2020 standard in point 3.2.2 defines it as a "Systematic approach that considers environmental aspects in design and development with the aim to reduce adverse environmental impacts throughout the life cycle of a product"[1]. Other commonly used terms are:

• Environmentally conscious design (ECD).
• Environmentally sustainable design.
• Green design.
• Design for Environment (DFE).

So, ecodesign and Design for Environment (DFE) have the same goals.

Life Cycle Assessment and DFE

Life Cycle Assessment (LCA) is a concept that evaluates the environmental impacts associated with all phases of a product's life, from raw material extraction through manufacturing, use, and end-of-life disposal. LCA typically assesses existing designs and considers the Bill of Materials (BoM) as part of these designs. In contrast, Design for Environment (DFE) provides technical recommendations for designers to create environmentally friendly products at the initial concept stage before even the BoM is established. Therefore, DFE can be seen as a precursor to LCA and overlaps with the LCA at the "detailed design" phase[2].

Ecodesign / DFE guidelines

Design for the Environment (DFE) guidelines should consider the entire product lifecycle, from raw materials to manufacturing, field operation, and disposal.

Note: Other methods from the a Design for X (DFX) toolbox also provide significant environmental benefits and often overlap with some aspects of DFE. For example:

• Design for Manufacturing (DFM) and Design for Assembly (DFA): These methods promote the reduction or simplification of the fabrication and assembly process and the standardization of components. Such solutions reduce the resources used, thereby overlapping with DFE principles.
• Design for Reliability (DFR): This method focuses on product reliability, leading to fewer failures and less waste. By reducing the need for replacement products, DFR conserves natural resources, creating another overlap with DFE.
• Design for Test (DFT): Simplifying the testing process, reduces energy usage (by minimizing unnecessary retesting), lowers failure rates, and decreases scrap levels. This results in less resource usage, further aligning with DFE objectives.

The following are aspects typically not covered by DFM, DFA, DFR, or DFT but typical to DFE. Use these aspects when creating product or industry-specific DFE guidelines.

Sustainable materials

Select materials that are more eco-friendly. Examples:

• Use bio-materials: Cork, natural fibers, plant-based polymers, etc.
• Add recycled materials: Paper-based packaging, recycled plastics (granulates), etc.
• Prioritize non-toxic materials: RoHS-compliant parts, Halide-free laminates, low-halide plastics, VOC-free fluxes, etc.
• Reduce rare earth elements (REEs): Replace REEs with alternative alloys, use ferrite magnets instead of neodymium magnets, etc.

Eco-friendly manufacturing

Design products with consideration for reducing waste or pollution during the manufacturing process. Examples:

• Specify eco-friendly materials: Select VOC-free and halide-free soldering fluxes, UV-curable conformal coatings, water-based paints, etc. It will reduce or even eliminate the emission of VOC compounds into the atmosphere.
• Allow product rework or repair: Some products that are scrapped due to nonconformities are relatively easy to rework or repair. Consider rework or repair where feasible.
• Allow to reuse components: Consider reusing some specific parts (from internal scraps at the manufacturer). Sometimes, entire products are scrapped due to some failure (e.g., electronic board failure), but there are mechanical parts that may be very easily removed and reused, such as large heatsinks, chassis, wiring, etc.

Energy efficiency

Design the product to be as efficient as possible. Reduce energy consumption. Consider the entire operation time of the product. Examples:

• Use high-efficiency power supplies: Implement resonant converters or photovoltaic-powered devices.
• Implement low-power mode operation: Incorporate features such as display dimming, sleep mode, and full power-off capabilities.
• Use components with lower power losses: Consider power components based on gallium nitride (GaN) or silicon carbide (SiC) in electronics. Use low Rds(on) MOSFETs, etc.

Waste & pollution reduction

Design products to minimize waste and pollution during use. Minimize harmful emissions and contaminants throughout a product's lifecycle. Reduce materials that users will most likely discard shortly after purchase. Examples:

• Use eco-friendly packaging: Utilize biodegradable, recyclable, or reusable packaging materials.
• Minimise packaging: Design packaging that uses the least material necessary while protecting the product during transport and storage.
• Minimize gas emissions. Incorporate design solutions to reduce gas emissions into the air. For example, ensure complete fuel combustion, use catalytic converters in products where applicable, and select materials that emit fewer gases during use. Use electric mode instead of combustion-based operation, etc.
• Minimize particulate emissions. Use effective filtering systems or select materials with lower particulate emission properties., etc.
• Minimize water or soil pollution. Select materials and operation methods to minimize water usage. Remove heavy metals from contact with water or soil. If applicable, use closed-loop systems to purify and reuse the water, etc.
• Minimize EMC. Design products to minimize unwanted electromagnetic emissions. Do your best to reduce emissions to lower levels than regulations require.

Repairability

Design the product in a way that allows product repair where possible. Examples:

• Modular Design: Design the product as a set of interconnected modules. It allows the replacement of failed parts without scrapping the entire product.
• Standardized Components: Standardize parts or modules. It will reduce the cost of spare parts and improve availability.
• Repair Manuals: Provide repair manuals, including diagnostics, disassembly, and reassembly instructions.

Dissasembly

When designing a product, it is crucial to incorporate features that facilitate easy disassembly and material separation. This approach supports recycling efforts and ensures the safe handling of hazardous materials. Here are essential guidelines to consider:

• Design for tool access: Ensure adequate product shape to allow tool access during disassembly. It reduces the time and effort required to take the product apart.
• Use standardized fasteners: Use standardized screws and connectors that can be easily removed with standard tools. Avoid using adhesives or permanent bonds that make disassembly difficult.
• Use modular components: Design the product in modular sections that can be independently removed and serviced. It makes replacing or upgrading parts easier without discarding the entire product.
• Disassembly instructions: Provide detailed instructions highlighting the tools needed and the steps involved. It can help both consumers and recycling facilities handle the product more effectively.
• Isolate hazardous components: Design the product to isolate hazardous materials from other elements. It simplifies their removal and reduces the risk of contamination during disassembly.
• Safe handling instructions: Clearly label hazardous materials and provide instructions for their safe handling and disposal.

Recycling

Recycling is a critical aspect of Design for Environment (DFE). It aims to reduce waste and conserve resources by ensuring that materials can be efficiently reclaimed and reused after a product has reached the end of its useful life. Here are some guidelines and considerations for enhancing recycling efforts within DFE:

• Clear material identification: Label different materials clearly to facilitate sorting and recycling. Comply with regulations related to part marking, such as "plastic resin identification code," etc.
• Avoid using composite materials: Design components to be made from single types of materials wherever possible.
• Select recyclable materials: Choose materials that are widely accepted by recycling facilities, such as certain plastics (e.g., PET, HDPE), metals (e.g., aluminum, steel), and glass.

Pros of DFE

• Environmental Benefits: Reduced ecological footprint, conservation of natural resources, and lower pollution levels.
• Economic Advantages: Potential cost savings from efficient resource use, energy savings, and reduced waste management costs, all of which align with the principles of Design for Cost (DFC).
• Regulatory Compliance: Easier adherence to environmental regulations and standards, potentially avoiding fines and penalties.
• Market Differentiation: Enhanced brand reputation and competitive advantage by offering eco-friendly products.

Cons of DFE

• Higher Initial Costs: Potentially higher upfront costs for sustainable materials and new technologies.
• Complexity in Implementation: Requires comprehensive product design, manufacturing process, and supply chain changes.
• Market Acceptance: Some consumers may be resistant to change or unwilling to pay a premium for eco-friendly products.

Standards and Guides

Several standards and guidelines have been developed to support designers in implementing DFE practices from a management system point of view. Key standards include:

• ISO 14006. Environmental management systems - Guidelines for incorporating ecodesign.
• ISO 14062. Environmental management - Integrating environmental aspects into product design and development.
• EN 16524. Mechanical products - Methodology for reducing the environmental impacts in product design and development.
• ISO 14040. Provides the principles and framework for conducting an LCA. It outlines the general principles, requirements, and guidelines to ensure that LCA studies are consistent and credible. This standard does not specify the methodological details or provide precise guidelines for the steps involved in LCA; instead, it establishes the overarching framework and terminology.
• ISO 14044. Specifies requirements and provides guidelines for LCA, ensuring a detailed and systematic approach. It builds upon the framework set by ISO 14040, offering more specific guidance on conducting LCA studies, including goal and scope definition, inventory analysis, impact assessment, and interpretation.
• EPEAT. Electronic Product Environmental Assessment Tool is a valuable system for evaluating the environmental impact of designed electronic products[3].

Regulations

There are many regulations related to products' impact on the environment. Following are some example UE directives:

• 2009/125/EC. Ecodesign requirements for energy-related products to improve their environmental performance throughout their lifecycle.
• 2010/30/EU. Energy labeling guidelines.
• 2011/65/EU. RoHS directive, first version was 2002/95/EC.
• 2012/19/EU. Waste electrical and electronic equipment (WEEE).
• 2019/424/EU. Ecodesign requirements for servers and data storage products.
• 2019/1782/EU. Ecodesign requirements for external power supplies.
• 2019/2021/EU. Ecodesign requirements for electronic displays.
• ESPR. Ecodesign for Sustainable Products Regulation (ESPR) - a new upcoming UE directive that will replace 2009/125/EC[4]

There are many regulations related to ecodesign. Visit the EU Lex webpage for more information[5].

Summary

Design for Environment (DFE) is a critical approach for developing sustainable products that minimize environmental impacts throughout their lifecycle. By focusing on lifecycle assessment, sustainable material selection, energy efficiency, waste reduction, and pollution prevention, DFE provides a comprehensive framework for creating eco-friendly products. Industry standards, guidelines, and many ecodesign-related legal requirements are essential inputs during product design. The designers shall understand the overall concept of Design For the Environment and apply it in the early phase of a product design.