Designing a new product is hard work; adding sustainability on top of it can feel overwhelming. This FAQ breaks down the most common questions and the practical answers to help you navigate the journey smoothly and confidently.
1. What does “sustainable product design” actually mean?
It means designing a product that minimizes environmental and social impacts along its entire lifecycle, from raw materials through to end-of-life.
It typically covers:
- Material selection
- Durability and repairability
- Energy efficiency
- Chemical safety
- Packaging
- Disposal and recycling
- Carbon footprint
It means making smarter, more durable, safer, and more transparent design decisions in practice.
2. Where to begin? It seems like everything is important.
Begin with material and substance compliance.
Identify regulatory frameworks that will apply before selecting materials or components: RoHS, REACH, POPs, TSCA, PFAS bans, packaging rules, battery regulations, EPR obligations, etc.
If your material choices are compliant right out of the gate, the rest of the sustainability strategy can be a lot easier.
3. How early in the design process should sustainability be considered?
From day one.
It is almost impossible to bolt sustainability on later; it has to be integrated at the concept level.
Early considerations reduce redesign costs, prevent compliance failures, and even open up new markets.
4. What are the most common mistakes companies make?
Choosing restricted or high-risk materials prematurely
Underestimating supply-chain transparency challenges
Ignoring expectations about repairability or durability
Treating sustainability as "optional" rather than as strategic
Not budgeting the time or resources for environmental testing
Designing packaging as an afterthought
Rushing into production without compliance documentation
5. How do I avoid selecting materials that will be banned later?
You can't predict everything, but you can reduce risk:
- Avoid very persistent substances (e.g., PFAS)
- Prefer recyclable and widely used materials.
- Use suppliers with strong compliance histories
- Monitor the upcoming regulations: SVHC additions, PFAS restrictions, battery rules, etc.
- Request early disclosure of chemical composition
- Essential tools are EPEC forms, BOM reviews, ChemSHERPA, IPC-1752A, and supplier questionnaires.
6. What role does design-for-recycling play?
A major one. Products that are designed for easy disassembly, separation of materials, and compatibility with the existing recycling streams reduce waste and may meet regulatory requirements (e.g. EU Ecodesign, France durability index etc.).
Focus on:
- Modular assemblies
- Screw-type fixing instead of glue
- Avoid material mixing: for example, metal-plastic inseparable composites
- Clear material markings
7. How can I design a product that lasts longer?
Build with repairability and durability in mind:
- Use standard fasteners
- Ensure replacement parts will be available
- Provide documentation for repair
- Choose robust materials and coatings
- Avoid weak points such as decorative chrome plating or brittle plastics.
- Also check the new rules, such as France’s Repairability & Durability Index.
8. How can I ensure the supply chain supports sustainability goals?
Communicate early and clearly. Ask suppliers for:
- Material declarations (RoHS, REACH SVHC, PFAS, etc.)
- Test reports
- Environmental Certifications
- Information on recycled content or responsible sourcing
- Avoid delays and inconsistencies by using structured forms and templates.
9. Is the use of recycled materials sustainable?
Not necessarily. Recycled materials are great when they:
Do not compromise on quality or durability.
Are traceable and safe
Meet regulatory chemical limits
Are compatible with the mechanical and environmental requirements of your product
Chemical compliance always needs to be checked; sometimes, recycled materials contain legacy contaminants.
10. How do I measure the sustainability of my product?
Common tools include:
- Life Cycle Assessment (LCA)
- Carbon footprint calculations
- Material footprint
- Durability scores and repairability indexes
- EPR cost modeling
- Chemical and substance compliance audits
Choose the tools that best match your industry, market, and budget.
11. What about packaging?
Packaging is now heavily regulated: EU Packaging Regulation, Canadian Plastic Registry, EPR systems
Design packaging that is:
- Minimal but protective
- Recyclable (paper/cardboard preferred)
- Free of PFAS, heavy metals, and PVC
- Easy to separate
Always check the local EPR rules where the product will be sold.
12. How important is documentation?
Critical.
Regulators, customers, and supply-chain partners expect:
- Material declarations
- Test reports
- Safety Data Sheets (SDS)
- Compliance matrices
- Traceability files: BOMs, Drawings, specifications
Good documentation can either make or break access to markets.
13. If sustainability adds cost, how do I justify it internally?
Show that sustainable design reduces long-term costs:
Fewer redesigns Lower EPR fees Fewer compliance failures Higher durability = fewer returns Stronger market differentiation Alignment with customer procurement requirements Sustainability is business strategy, not charity.
14. How can I survive the whole process without going crazy?
Break it into phases: concept → materials → compliance → testing → documentation Utilize expert support where necessary: labs, consultants, testing partners Standardize communication with suppliers using structured forms. Don't reinvent everything: reuse proven parts and materials Keep regulations bookmarked and updated Celebrate small wins-sustainability is a marathon, not a sprint! 15. What is the number one piece of advice for a new sustainable product designer? Ask the right questions early. Knowing your materials, your risks, your supply chain, and your regulatory obligations from the outset makes sustainability a powerful driver of design, not a roadblock.
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