Embodiment Design and Technologies

Roland Lachmayer (), Johanna Wurst () and Jorin Thelemann ()
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Roland Lachmayer: Leibniz Universität Hannover, Institut für Produktentwicklung und Gerätebau (IPeG)
Johanna Wurst: Leibniz Universität Hannover, Institut für Produktentwicklung und Gerätebau (IPeG)
Jorin Thelemann: Leibniz Universität Hannover, Institut für Produktentwicklung und Gerätebau (IPeG)

Chapter Chapter 10 in Methodology for the Development of Sustainable Products, 2026, pp 147-160 from Springer

Abstract: Abstract This chapter shifts from conceptual rules to the embodiment design of sustainable products, where ideas become manufacturable structures. Embodiment design defines geometry, topology, tolerances, materials, and surfaces, balancing technical performance with production feasibility. Methods such as structural element combination, systematic variation, and numerical optimisation guide this process, resolving conflicts iteratively through modelling and calculation. Lightweight design is a central theme, reducing resource demand and energy use by minimising mass without compromising function. Techniques include topology optimisation, material substitution, cavity integration, and structural stiffening, applied in aircraft, automotive, and household products. Efficient material use lowers costs and emissions while improving energy efficiency and durability. Three domains illustrate sustainability integration: additive manufacturing, bio-based composites, and wood. Additive manufacturing offers design freedom, localised production, reduced transport, and waste, enabling topology-optimised, repairable, and recyclable parts. Bio-based composites use renewable fibres like hemp or flax in polymer matrices, balancing strength, low weight, and environmental benefits but facing challenges in standardisation and durability. Wood, with low weight, damping, and a positive CO2 balance, re-emerges as an engineering material for logistics and mobility applications. Case studies demonstrate its potential to substitute metals or plastics. Overall, embodiment design unites principles, materials, and technologies to realise sustainable, circular products.

Date: 2026
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DOI: 10.1007/978-3-662-72442-2_10

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