The Designer/'s Field Guide To Sustainability
the designer’s field guide to sustainability
an overview of sustainable product development and the product life cycle
Question the premise
of the design
Make it modular
WHERE DOES
Consider other approaches to
Modular designs are more
easily repaired, and recycled
IT END UP?
the problem at hand
Make is less complex
Maximize recycled, recyclable, renewable,
Simple, elegant designs are
and biodegradable materials
often the least impactful
PET, Polypropylene, HDPE, Wood,
Steel, Aluminum and PLA for example
Make it more useful
Multiuse products can reduce
Minimize fasteners
consumption and increase convenience
Fasteners add weight, material variety
and assembly/disassembly complexity
Don’t use paint
Painted plastics are
WHAT IS IT TRYING
04 01
less likely to be recycled
TO ACCOMPLISH?
HOW IS
Reduce material variety
IT USED?
This can increase recyclability and can
03 02
BROUGHT T H
decrease manufacturing energy
Design for Upgradeability
O
Avoid toxic or harmful
Make standard internal components
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materials and chemicals
accessible and self explanatory
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PVC, polystyrene, lead and BPA for example
Create durable and high quality designs
S
Reduce size and weight
Make products people want
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This reduces emissions during shipping
to keep…and make them last
T
Optimize manufacturing processes
Design for life after death
O LIFE?
Powder coat vs. paint. Pressure form vs. RIM
A secondary use for a product
Talk to your manufacturers about low energy,
adds value and helps reduce waste
low waste alternatives
Design packaging in
parallel with products
A green product in a wasteful package
should be avoided whenever possible
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q u e s t i o n t h e p r e m i s e
o f t h e d e s i g n
m a k e i t l e s s c o m p l e x
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a v o i d t o x i c o r h a r m f u l
m a k e i t m o r e u s e f u l
r e d u c e m a t e r i a l v a r i e t y
m a t e r i a l s a n d c h e m i c a l s
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o p t i m i z e
m a n u f a c t u r i n g
d e s i g n p a c k a g i n g i n
d e s i g n f o r
c r e a t e d u r a b l e a n d
r e d u c e s i z e a n d w e i g h t
p r o c e s s e s
p a r a l l e l w i t h p r o d u c t s
u p g r a d e a b i l i t y
h i g h q u a l i t y d e s i g n s
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e l e m e n t s
elements@lunar.com
m a x i m i z e r e c y c l e d ,
http://lunarelements.blogspot.com/
r e c y c l a b l e , r e n e w a b l e ,
d e s i g n f o r l i f e
a n d b i o d e g r a d a b l e
d o n ’ t u s e p a i n t
a f t e r d e a t h
m a k e i t m o d u l a r
m a t e r i a l s
m i n i m i z e f a s t e n e r s
i f p o s s i b l e
thank you!
the designer’s
field guide to
sustainability
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WHERE DOES
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WHAT IS IT TRYING
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HOW IS
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BROUGHT T HO
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an overview of sustainable product development
and the product life cycle
WHAT IS IT TRYING TO ACCOMPLISH?
HOW IS IT BROUGHT TO LIFE?
q u e s t i o n t h e p r e m i s e o f t h e d e s i g n .
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r e d u c e m a t e r i a l v a r i e t y .
Consider other approaches to the problem at hand. Is the form factor that you had in mind really
Designing as many aspects of the product as you can from the same material makes recycling the
the best way of accomplishing the task? Is any form factor the best way of accomplishing the task?
product at its end of life easier, more efficient, and more profitable.
Maybe a service fits the mold better? Perhaps the answer lies within an existing product?
Example: At its Chupai, Taiwan plant, Philips
Watch out: Be sure to not use harmful ma-
Example: Instead of designing a special arm Watch out: Be sure to always consider a cli-
Electronics designed the Typhoon, a high-end
terials in the name of reducing material vari-
band to carry a runner’s keys during a work-
ent’s economic performance goals when ap-
color monitor, using green product design
ety. Non-recyclable, non-renewable and toxic
out, design a running sock with a key pocket. plying this method. Even though a behavioral
techniques. As a result, the monitor requires
materials should generally be avoided when
People are going to buy socks anyway. Got a change could solve the problem at hand (like
35 percent less time to manufacture than a
possible. Deciding early on to use recycled,
better example? Go to LUNAR’s sustainabil-
putting a key under the mat, in this exam-
conventional monitor due to a 42 percent re-
recyclable, renewable and biodegradable ma-
ity blog at http://lunarelements.blogspot.com/ ple) the client would be left without a prod-
duction of material and components.
terials for major components of the design
and post it for the world to see.
uct. Suggesting that they move to a sock
will help reduce material variety without neg-
instead of an armband may still meet their
ative side effects.
financial objectives.
a v o i d t o x i c o r h a r m f u l
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m a k e i t l e s s c o m p l e x .
m a t e r i a l s a n d c h e m i c a l s .
Materials like PVC, neoprene or polystyrene, and toxic chemicals and additives like bisphenol
Simple, elegant designs can reduce material, weight, and manufacturing processes. Simple designs
A and formaldehyde should be avoided when possible. Many of these materials have suitable
usually also mean less material variety and can help make a product more recyclable.
non-toxic counterparts, like copolyesters or bioplastics, and additives can be eliminated by
choosing materials wisely.
Example: Benjamin stools from IKEA are a
Watch out: Keeping designs simple can some-
simple and elegant design. They are made of
times lead to overlooking an opportunity to
a single material, with a utilitarian but elegant
increase the usefulness of a product without
Example: Nalgene water bottles have recently
Watch out: Make sure to consider the en-
form factor. This makes them lightweight
increasing its ecological impact (see below).
switched one of their material selection (a
ergy input for the entire production cycle of
and incredibly portable. They can be used
polycarbonate that contained bisphenol A) to
the alternative material chosen and the likely
as a sitting stool, a stepping stool, a coffee
a copolymer with almost identical properties
disposal method for the product. If proper
table, etc.
but without the associated health risks.
disposal or recycling can be guaranteed, less
friendly materials may be a safe, best per-
forming, lowest energy material choice
for the job.
m a k e i t m o r e u s e f u l .
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At first glance, this may seem to contradict point number 2, but there is a big difference between
usefulness and complexity. Taking advantage of a natural or logical extra use for a product will not
r e d u c e s i z e a n d w e i g h t .
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only make the product more desirable and interesting, it will also help reduce the number of prod-
Lightweight products can reduce carbon emissions and cost by making the shipping process more
ucts headed for landfills. Multiuse products can reduce consumption and increase convenience.
efficient. Weight can often be saved by focusing on choosing lightweight materials, simplifying
designs, and eliminating unnecessary fasteners and components.
Example: The shape of the flat-head screw-
Watch out: Be careful not to let added use-
driver on many pocket knives has been clever-
fulness detract from the functionality of the
Example: The HP Pavilion Slimline PC is 1/3
Watch out: Don’t sacrifice durability in the
ly designed to also function as a bottle opener.
product. Poor functionality can lead a con-
the size and half the weight of a traditional
name of weight savings. Less durable prod-
The usefulness of the device has increased
sumer to abandon the product altogether for
tower PC. Using weight/space-saving design
ucts need to be replaced more often and ship-
with no added material or complexity.
a better functioning model.
approaches, HP and LUNAR were able to cre-
ping a lightweight item twice can cause more
ate a design that delivers all the processing
harm than shipping a heavier one once.
power and features of a regular PC with less
impact on the planet.
o p t i m i z e m a n u f a c t u r i n g p r o c e s s e s .
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HOW IS IT USED?
Determine which manufacturing processes make the most sense for your product. For lower
volumes or less complex parts, consider vacuum forming instead of injection molding. For some
complex metal geometries consider casting instead of machining.
d e s i g n f o r u p g r a d e a b i l i t y .
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In the electronics industry, the technology in a product can become obsolete long before the design.
Example: When a metal must be coated,
Watch out: Manufacturing processes are
Designing products that can be upgraded to keep up with rapidly changing technical performance
consider powder coating instead of painting.
complex systems and often energy or materi-
can save materials and money.
The powder coating process allows for excess
als waste can be hidden within these systems.
powder to be collected and reused in the
Talk with your manufacturer to make sure you
Example: The HP MediaSmart Server was de-
Watch out: Products that are designed to be
coating process, as opposed to paint over-
understand the entire process and consult in-
signed with simple upgradeability at its core.
upgradeable without being designed to be du-
spray, which cannot be recovered.
dexes like the OKALA 07 impact factors table
Purchasable with varying starting amounts of
rable may break before they are ready for an
to make sure that all aspects of the process
storage, its capabilities can be upgraded by
upgrade. This could result in adding undue
are considered.
simply adding a drive when the time is right:
complexity to a design that won’t be upgraded
a process that HP and LUNAR made sure was
after all.
a simple task for all.
d e s i g n
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p a c k a g i n g i n p a r a l l e l w i t h p r o d u c t s .
If a product is designed with a stylish and sustainable packaging scheme in mind, a client might
absorb that idea. Lightweight packaging that uses sustainable (recycled, recyclable, or biodegrad-
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c r e a t e d u r a b l e a n d h i g h q u a l i t y d e s i g n s .
able) materials can reduce carbon emissions and raw materials waste alike.
People want high quality products that will look and function beautifully long after the competing
product has died, and they’re willing to pay a little more for that type of design. Designed properly,
Example: P&G’s focus on packaging in the
Watch out: Always keep in mind that unneces-
products can transcend the “throw away” culture that dominates electronics today.
last 15 years has produced staggering results.
sary packaging complexity, while sometimes
According to bsr.org, “The company has used
creative, is unnecessary. Remember that all
Example: Craftsman hand tools have estab-
Watch out: Not all products should last forev-
computer models to develop products that
of the tips in this guide pertain to packaging
lished a well earned reputation for being built er. Inherently limited use or single use prod-
are more concentrated and require less pack-
design as well.
to last. While some brands of less expensive ucts, like medical disposables, food packag-
aging, such as bottles that are stronger yet
tools are cast with shoddy processes causing ing, toothbrushes (the heads, at least) should
lighter in weight, packages that do not require
them to fail, Craftsman has built their brand be designed to be the opposite of durable.
outer cartons, and the use of stronger lighter
on selling high quality, durable tools, and Design temporary items to be absorbed back
materials in place of heavier ones.” The re-
backing them up with a no questions asked into the technical nutrients chain by making
sults of this packaging design blitz are that
lifetime warranty.
them fully recyclable, or back into the earth by
“overall packaging per case has been reduced
making them biodegradable or compostable.
by 27% and waste, air and water emissions
have been reduced by 37%” since 1990.
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d e s i g n f o r l i f e a f t e r d e a t h .
Most products don’t last forever. Products designed to have secondary usages after their primary
function has lapsed can add value to the product, and may fill a need that would be filled by
another purchased product instead.
Example: Adding graduated lines to the side
Watch out: Trying to work unnecessary sec-
of a salad dressing bottle makes it useful as a
ond uses into a design can often increase
measuring device after its initial use.
the complexity. Design a product’s second
life such that it requires no extra parts or
complexity that wouldn’t be needed in the
original design.
WHERE DOES IT END UP?
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m i n i m i z e f a s t e n e r s .
Minimizing fasteners can make large portions of the product more easily recyclable at the end of
life since removing snap-on parts can be done completely and quickly without the use of tools. This
m a k e i t m o d u l a r .
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also eliminates multiple fasteners from the product BOM and reduces the amount of assembly time
necessary to get products out the door, which reduces cost on two fronts.
Modular designs are not only more easily recycled at the end of their life but also more easily
repaired, and therefore last longer. Modular designs can also be more efficiently manufactured and
Example: Dell computer bezels are assem-
Watch out: Sometimes a single fastener can
shipped, reducing energy consumption at the beginning of the product’s life.
bled with snaps that are had for “free” by in-
avoid large amounts of part complexity and
tegrating them into the design of the part that
material variety. Also, if the fastener is made
Example: An example of this principle is the
Watch out: Making designs overly compli-
is already being injection molded. This also
of the same material as the parts it is join-
Aeron Chair by Herman Miller. One of the
cated in order to make them modular can do
allows them to be more easily accessed for
ing, the entire assembly may be able to be
design considerations for the Aeron was to
more harm than good. Adding extra fasten-
maintenance and more easily separated for
recycled without disassembly.
make it “…sparing of natural resources, du-
ers, brackets, and materials opposes tips 3
recycling at the end of their lives.
rable and repairable, designed for disassem-
and 4. Try to design for modularity that can be
bly and recycling.” As a result, Aeron chairs
had for “free” using creative features on in-
are not sent back to retailers for repair.
jection molded parts or pieces of sheet metal
Instead, if the chair breaks, replacement
that can accomplish multiple tasks.
d o n ’ t u s e p a i n t .
parts are ordered and the chairs are easily
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repaired on site.
Painting a material generally makes it harder to recycle at the product’s end of life because the
paint cannot be easily separated from the material. As a result, many painted products are either
not recycled or are irresponsibly melted down to burn off the paint, creating toxic fumes and lower
quality recycled material. Design products to take advantage of the natural beauty of materials.
u s e r e c y c l e d , r e c y c l a b l e , r e n e w a b l e ,
a n d b i o d e g r a d a b l e m a t e r i a l s .
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Example: The HP Photosmart 7850 printer
Watch out: Eliminating paint on appear-
This one’s obvious, but should always be kept in mind. Design with recycled or easily recyclable
has plastic parts made almost entirely out
ance parts could result in lower yields in the
plastics (HDPE, PP, PS, PVC), biodegradable plastics (PLA, PHB, polyamide, bio-derived poly-
of highly recyclable, non-painted plastics. In
molding process. Discuss this with the part
ethylene), paper, cardboard, wood, stainless steel, aluminum, etc.
addition to making the plastic components
manufacturer to determine acceptable yield
more easily recyclable, having mold-in color
rates. Also verify that unusable parts will be
Example: San Francisco based Green Toys
Watch out: Sourcing sustainable materials
means they can be scratched or worn without
reground and reused to make good parts.
makes children’s toys entirely out of recycled
from distant locations can sometimes prove
degrading their appearance. This choice also
milk jugs from local recycling facilities. All
more harmful than beneficial. Biodegradable
saves HP the costs associated with adding a
of the Green Toys products are both recycled
plastics produced in Australia, molded in Chi-
painting stage in the manufacturing process.
and recyclable.
na, and then shipped to the US can be more
detrimental than standard plastics produced
and manufactured closer to the product’s
point of sale.
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