Integrating Absolute Sustainability in Product Design: A Case Study within the Manufacturing Industry

06/18/2025

In the current global context, where the planet faces increasingly severe environmental degradation and surpasses several planetary boundaries, it is essential to rethink how consumer products are designed. This project explores the application of absolute sustainability principles in the redesign of a conventional cleaning mop, with the aim of drastically reducing environmental impact without compromising functionality or user needs. The process began with an in-depth analysis of existing Fapil models and the main environmental factors associated with materials, manufacturing, use, and end of life. Through a structured generation of concepts, selection, and iterative prototyping, a final design was achieved that incorporates sustainable materials and features a modular format. This modularity facilitates the separation and washing of the fibres in conventional washing machines, prolonging the product's lifespan and enabling recycling and maintenance. Recycled polypropylene was used in the structural components, and waste from diaper factories was reused in the fibres, making use of resources and reducing waste. Furthermore, the project introduced a plantable, plastic-free packaging concept that serves both protective and symbolic functions. A Life Cycle Assessment (LCA) confirmed a significant reduction in environmental impact compared to traditional alternatives, although some planetary boundaries are still exceeded. The project highlights the challenges and opportunities of integrating absolute sustainability into real-world product design. Despite some limitations, the result represents significant progress and establishes a replicable methodology that can guide future sustainable innovations.

Authors in the community:

• 

  M

  Marta Poch Mascaró

  ist1112556

Supervisors of this institution:

• 

  G

  Gonçalo Nuno Alfredo Cardeal

  ist170375

• 

  E

  Elsa Maria Pires Henriques

  ist13187

mechanical-engineering - Mechanical engineering

eng - English

Instituto Superior Técnico