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New design platform allows engineers to think more sustainably

  • Researchers at RIT’s Golisano Institute for Sustainability have developed PhoenixDFR, a software tool that helps engineers design products with remanufacturing in mind.
  • The tool uses real-world industry data to flag design issues and guide improvements through web and CAD-based platforms.
  • The team worked closely with companies from multiple sectors, including heavy equipment, HVAC systems, and automotive.
     

Brian Hilton, principal investigator (PI) and engineering manager at Golisano Institute for Sustainability (GIS), has been searching for solutions to an increasingly disposable society. When his 9-year-old refrigerator started failing, the repair quote came in at a price that was higher than the price of a new unit.

“There was a leak in the line somewhere,” Hilton said. “From an engineering standpoint, that should have been an easy fix. But the repair technician told me that given the difficult access to the lines and the lack of system modularity, I’d be better off buying a new one.”

That experience reflects a larger, global problem in product development—most products are not designed with longevity in mind and may contain features that make a second life technically or economically unfeasible.

To help solve this problem, engineers at GIS have developed a new software platform to help manufacturers design products that are easier to remanufacture. The tool, named PhoenixDFR, helps engineers think about sustainability earlier in the design process. The tool works both as a web app and as plug-ins within popular computer-aided design (CAD) software.

PhoenixDFR helps engineers evaluate product parts for attributes that could hinder remanufacturing, such as excessive wear, corrosion, or general material loss. The tool then guides users through a step-by-step decision process that highlights design fixes and workarounds, then generates a detailed report with screenshots, design suggestions, and a performance score based on a custom scoring system built by the team.

“We're not trying to tell the design engineer what to do,” said senior engineer Frank Zelinger.  “A design engineer and a product manager will still weigh things like cost into the equation, but now you've given them another piece of information to think about.”

The system draws on a growing database of 25 remanufacturing failure modes and hundreds of design rules, collected from industry papers, textbooks, and during site visits to different manufacturers.

“They opened their doors and let us basically go dumpster diving at the end of a remanufacturing line,” Hilton said. “We asked a ton of questions and got insights that go beyond what you’d typically find in a concise journal article.”

Hilton said the team visited five sites across the country and worked closely with companies from multiple sectors, including heavy equipment, HVAC systems, and automotive.

“Having them be open to sharing pre-competitive information was a very important part of this,” he added. “It’s been a strong collaboration, and we couldn’t have done this without industry in the room.”

The team working on this project consists of Hilton, Zelinger, and senior engineer/Co-PI Scott Nichols, who leads software development. They were aided by a group of RIT co-op students, including and former co-op student and 2023 graduate Miko Buenk and third-year computer science student Jared Randall. They helped quantify environmental impacts of remanufacturing and address cybersecurity of the tool for use in industry settings, respectively.

PhoenixDFR was built with heavy equipment and industrial components in mind, but the team sees opportunities to expand into other product sectors—including consumer electronics, transportation systems, and appliances like Hilton’s refrigerator.

“There’s no reason why the principles behind this tool can’t apply to everything from kitchen equipment to laptops,” said Hilton. “Any time you can extend the life of a product, you’re getting more value out of the materials, energy, and labor that went into it.”

Although still in beta testing, PhoenixDFR is already generating strong interest among manufacturers. The team is exploring commercialization options.

“We want to push the envelope,” Hilton said. “We want people to think more about circularity and think more about sustainability and how to integrate that into product development. But today, let's work on remanufacturing.”

The tool began development in 2023, thanks to $1.96 million in grants from the REMADE Institute, a public-private partnership and Manufacturing USA innovation institute funded in part by the U.S. Department of Energy and Empire State Development.

This material is based upon work supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Advanced Manufacturing Office Award Number DE-EE0007897 awarded to the REMADE Institute, a division of Sustainable Manufacturing Innovation Alliance Corp. In addition, RIT received funding, in part, from New York State Empire State Development under grant #AC118 that supported the work on this project. The views expressed herein do not necessarily represent the views of the U.S. Department of Energy, the United States Government or New York State.

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