Lightweight Design and Circularity in Product Development

This technical report addresses the integration of lightweight design and design for circularity within the context of product development. It presents the concept of functional life cycle energy analysis (FLCEA), which divides product architecture into functions with allocated energy consumptions, serving as a cross-stage indicator for expected resource consumption throughout the product life cycle. The report outlines the synergies and conflicts between lightweight design and design for circularity, emphasizing the importance of decision-making in the early phases of product development. The methodology is illustrated through a use case in robotics, highlighting the potential for holistic optimization across three life cycle stages. The report also discusses the challenges posed by advanced lightweight solutions and their implications for resource consumption. By systematically supporting engineers in identifying optimization potentials, the proposed methodology aims to facilitate the responsible use of resources in future product generations.