A SUSTAINABLE AND GREEN PROTOTYPING FRAMEWORK FOR LOW-CARBON AND RESOURCE-EFFICIENT VIRTUAL PRODUCT DEVELOPMENT

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Year : 2026 | Volume : 14 | 03 | Page :
    By

    Khiraling Patil,

  • Sachhidanand Reur,

  • Ashok Kumar Vanageri,

  1. Research Scholar, Department of Industrial and Production Engineering, PDA College of Engineering, Kalaburgi, Karnataka, India & Visvesvaraya Technological University, Belagavi, Karnataka, India
  2. Professor, Department of Industrial and Production Engineering, PDA College of Engineering, Kalaburgi, Karnataka, India & Visvesvaraya Technological University, Belagavi, Karnataka, India
  3. Professor, Department of Mechanical Engineering Basavakalyan Engineering College, Basavakalyan Karnataka, India & Visvesvaraya Technological University, Belagavi, Karnataka, India

Abstract

The increasing emphasis on sustainable manufacturing has intensified the need for environmentally responsible design and development methodologies for polymer and polymer-composite materials, where material selection, processing routes, and waste generation play a critical role in overall environmental impact. This paper presents a Sustainable and Green Prototyping (SGP) framework that integrates Virtual Prototyping (VP), Life Cycle Assessment (LCA), and multi-objective optimization to systematically reduce carbon footprint, energy consumption, and material waste throughout the polymer composite product development process. The proposed framework is structured into three interconnected levels: (i) CAD/CAE-based virtual modeling and simulation of polymer and composite components, enabling early-stage evaluation of material behavior and manufacturability, (ii) embedded LCA, which quantifies environmental impacts associated with raw materials, composite manufacturing processes, and end-of-life scenarios, and (iii) Pareto-based decision-making, allowing simultaneous optimization of sustainability, performance, and production-related constraints. The applicability of the framework is demonstrated through automotive, electronics, and consumer product case studies, focusing on thermoplastic and thermo set polymer composites, fiber-reinforced polymers, and lightweight molded composite components commonly employed in industrial applications. The results indicate that the SGP framework achieves reductions of 30–38% in carbon emissions, 24–33% in energy consumption, and 35–43% in material waste when compared to conventional VP-based prototyping approaches. In addition, the optimization engine reveals inherent trade-offs among sustainability indicators and processing choices, enabling the selection of eco-efficient polymer composite materials and manufacturing strategies without compromising cost, quality, structural integrity, or production lead time. Overall, the proposed SGP framework provides a practical, industry-ready approach for integrating sustainability into polymer composite design and processing, supporting the transition toward circular economy principles, Industry 4.0-enabled manufacturing, and low-carbon composite production systems.

Keywords: Sustainable and Green Prototyping; Polymer and Composite Materials; Virtual Prototyping; Life Cycle Assessment; Multi-objective Optimization; Low-carbon Manufacturing; Circular Manufacturing; Industry 4.0

How to cite this article:
Khiraling Patil, Sachhidanand Reur, Ashok Kumar Vanageri. A SUSTAINABLE AND GREEN PROTOTYPING FRAMEWORK FOR LOW-CARBON AND RESOURCE-EFFICIENT VIRTUAL PRODUCT DEVELOPMENT. Journal of Polymer & Composites. 2026; 14(03):-.
How to cite this URL:
Khiraling Patil, Sachhidanand Reur, Ashok Kumar Vanageri. A SUSTAINABLE AND GREEN PROTOTYPING FRAMEWORK FOR LOW-CARBON AND RESOURCE-EFFICIENT VIRTUAL PRODUCT DEVELOPMENT. Journal of Polymer & Composites. 2026; 14(03):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=243349


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Ahead of Print Subscription Original Research
Volume 14
03
Received 02/02/2026
Accepted 06/03/2026
Published 09/05/2026
Publication Time 96 Days
70

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