Introduction to Product Lifecycle

Every product has an environmental story—from raw material extraction to end-of-life disposal. Lifecycle Assessment (LCA) quantifies impacts across five critical stages: Design dictates 70-80% of environmental footprint before manufacturing begins. Material selection alone determines embodied carbon (steel: 2 kg CO2e/kg; aluminum: 8 kg CO2e/kg; carbon fiber: 20+ kg CO2e/kg). Manufacturing processes add 15-30% of emissions through energy use, waste generation, and water consumption. Energy-intensive processes like smelting, casting, and chemical synthesis dominate this phase. Use phase varies wildly by product type: For active products (vehicles, appliances), it's 40-70% of lifecycle emissions. For passive products (furniture, buildings), it's minimal. A car's use phase accounts for 75% of lifecycle CO2; a smartphone's manufacturing is 85%. End-of-life management closes—or breaks—the loop: Recycled aluminum uses 95% less energy than virgin production. Landfilling wastes embodied energy and creates methane. Circular economy strategies (reuse, remanufacturing, recycling) can cut lifecycle emissions 30-60%. Design choices cascade through all stages: Lightweight design reduces use-phase energy but may increase manufacturing complexity. Modular design enables repair and remanufacturing. Design for disassembly facilitates recycling.