There is a growing recognition of the need to incorporate sustainability considerations early-on in the product development (PD) process (PDP). As part of a case study at an engineering consultancy firm, this paper identifies considerations that influence the integration of sustainable design practices into real-world PD practices. This is informed by the first author becoming embedded in the firm as an intern, and closely observing the PD workflow across various projects, conducting interviews and group discussions with a wide range of practitioners, and iteratively designing and testing various potential interventions. From the literature and observations, we find that designers and engineers often struggle to identify and apply the right sustainable design methods and tools (SDMTs) to tackle the environmental impacts associated with their products. Through a human-centered design process, we co-created a reusable, modular framework of practices that aids the selection of relevant strategies, based on the environmental hotspots, stage of the PD process, and the client’s sustainability priorities. Our prominent findings highlight the importance of: (a) co-creation in enhancing receptivity and retention, (b) the use of LCA iteratively to inform design decisions throughout PD, and (c) sharing case studies of successful application of the framework to promote sustainable design among employees and clients, alongside several other takeaways. The paper further presents insights related to the framework’s real-world application and impacts in the firm, based on results of longitudinal engagement with the firm.

How do employees perceive the impact of incorporating sustainability considerations into their product development practice? In this case study, we observe how these perceptions can be shifted by teaching workshops on how to apply sustainable design methods in practice. We compare the trends for different methods on various dimensions such as creativity, design process time, product marketability etc. Results show an overall shift towards positive perception for all the methods on a majority of factors, indicating a way to ease the adoption of sustainable design into industry practice.

Do different sustainable design methods generate different sustainable design ideas? Do they also drive different product innovation ideas? This project empirically tested three design methods: The Natural Step, Whole System Mapping, and Biomimicry. Testing involved qualitatively categorizing 1,115 design ideas from 23 workshops for over 30 companies, including consultancies and manufacturers in consumer electronics, furniture, and apparel. The categorized ideas were then counted to determine if the different design methods caused different kinds of ideas. They did. For example, The Natural Step drove more ideas on green material choice, circular end of life, and social impacts, while Biomimicry drove more durability ideas and Whole System Mapping drove more cost reduction ideas, among other differences. Overall, The Natural Step generated the highest percentage of sustainability ideas, Biomimicry generated the most innovation ideas, and Whole System Mapping generated a balance of both. These preliminary results should help designers and engineers choose design methods suited to the types of design solutions they desire.