An Approach for Idea Generation on Sustainable and Circular Products in the Early Phase Exemplified by a Vehicle Component

Overview

The paper addresses the integration of sustainability and circular economy principles into early-stage product innovation, particularly within the automotive sector. It examines how fundamental product specifications—including material selection, construction methodology, joining techniques, design, production processes, and repair strategies—are determined primarily during initial development phases. The study identifies a gap between theoretical data-driven evaluation and the incorporation of tangible prototypes in decision-making processes during early innovation stages.

Methods and approach

An approach for sustainability-oriented and circular product ideation in early phases is developed and tested through application to a vehicle component case study (center console). The methodology emphasizes the inclusion of physical prototypes alongside data-based evaluation rather than deferring prototype development to later stages. This framework integrates disruptive, sustainability-oriented ideation with tangible realization to support informed decision-making processes that account for material composition, construction techniques, assembly methods, design specifications, manufacturing approaches, and end-of-life recovery strategies.

Key Findings

The application to the center console component demonstrates the viability of integrating physical prototyping with early-stage sustainability-oriented ideation. The approach facilitates more comprehensive evaluation of product concepts by combining theoretical analysis with empirical prototype assessment. Results indicate that this integrated methodology enables better-informed decisions regarding fundamental product characteristics that align with circular economy and sustainability objectives, particularly within the context of emerging automotive technologies such as electric vehicles.

Implications

The findings suggest that incorporating physical prototypes in early innovation phases enhances the quality of sustainability-oriented design decisions compared to theory-alone approaches. This has relevance for automotive manufacturers navigating regulatory requirements and strategic shifts toward circular business models, as disruptive design solutions require validation beyond computational or theoretical frameworks. The approach potentially reduces downstream design modifications and supports more coherent alignment between early-stage conceptualization and sustainability objectives mandated by EU legislation.