This study proposes a novel environmental indicator and a dimensionless score to support the assessment of vehicle component substitution strategies, particularly in lightweight redesign applications. The method was developed to provide a rapid and transparent comparison between a baseline component and a redesigned alternative with equivalent mechanical performance, accounting for the full life cycle contribution of production, use phase, and end-of-life (EoL). The indicator can be applied to any environmental category for which consistent characterization factors are available. In this work, it was tested using Global Warming Potential over 100 years (GWP100), water use, and non-renewable energy resource consumption. A score is calculated as the ratio between the environmental indicators of the redesigned and baseline components, enabling immediate classification into environmental performance classes. The methodology was demonstrated through two case studies, i.e., an automotive bracket–damper system and an aeronautical tablet holder, both redesigned according to Design for Additive Manufacturing principles. Results show that while additive manufacturing generally increases production-phase burdens, mass reduction during operation can significantly offset these impacts, particularly in high-intensity transport systems. In the automotive case, the redesigned component reduced GWP100 and non-renewable energy resource consumption, while water use increased; in the aeronautical case, environmental benefits were obtained across all three categories. A complementary break-even analysis was introduced to identify, when applicable, the minimum operating life required for the redesigned solution to become environmentally advantageous. The proposed method offers a practical, component-oriented complement to full LCA, supporting environmentally informed design decisions during early development stages.
A dimensionless life-cycle environmental indicator and a decision-oriented score for assessing vehicle component substitution
Savio, Gianpaolo;
2026
Abstract
This study proposes a novel environmental indicator and a dimensionless score to support the assessment of vehicle component substitution strategies, particularly in lightweight redesign applications. The method was developed to provide a rapid and transparent comparison between a baseline component and a redesigned alternative with equivalent mechanical performance, accounting for the full life cycle contribution of production, use phase, and end-of-life (EoL). The indicator can be applied to any environmental category for which consistent characterization factors are available. In this work, it was tested using Global Warming Potential over 100 years (GWP100), water use, and non-renewable energy resource consumption. A score is calculated as the ratio between the environmental indicators of the redesigned and baseline components, enabling immediate classification into environmental performance classes. The methodology was demonstrated through two case studies, i.e., an automotive bracket–damper system and an aeronautical tablet holder, both redesigned according to Design for Additive Manufacturing principles. Results show that while additive manufacturing generally increases production-phase burdens, mass reduction during operation can significantly offset these impacts, particularly in high-intensity transport systems. In the automotive case, the redesigned component reduced GWP100 and non-renewable energy resource consumption, while water use increased; in the aeronautical case, environmental benefits were obtained across all three categories. A complementary break-even analysis was introduced to identify, when applicable, the minimum operating life required for the redesigned solution to become environmentally advantageous. The proposed method offers a practical, component-oriented complement to full LCA, supporting environmentally informed design decisions during early development stages.
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