Sustainable mechanical design with material selection and lifecycle analysis for eco-friendly products

Environmental concerns are inherent in mechanical design intended to incorporate sustainability concepts into product development in order to reduce ecological footprints while retaining expediency and cost-effectiveness. The paper discusses various methodologies in selecting ecological materials and analyzing life-cycle assessment for better sustainability in mechanical systems. It emphasizes the linking of computer-aided design (CAD), computer-aided manufacturing (CAM), and finite element analysis (FEA) with sustainable practices. CAD enables lightweight and resource-efficient designs, CAM minimizes waste through precision manufacturing, and FEA validates the structural integrity within resource constraints. The bicycle frame design was supported with a case study on using bio-based composites, LCA-based substitution of materials, and simulation-based optimization, demonstrating a 30% reduction in carbon emission compared to conventional aluminum frames. The findings emphasize the vital role of digital tools in merging sustainability and engineering performance.