Integrating DFMA and Sustainability Assessment for Mini-Fan Redesign: A Comparative Case Study

Abstract

The environmental performance of small consumer products can be improved when manufacturability and life-cycle considerations are incorporated before detailed design is fixed. This study integrates Design for Manufacturing and Assembly (DFMA) principles with a screening-level, CAD-based sustainability assessment to compare a baseline mini-fan with a redesigned alternative. The baseline assembly was modelled in SolidWorks 2020, and the main housing, battery casing, and base were modified through geometric simplification and material-volume reduction. Both alternatives were evaluated using identical manufacturing processes and regional settings. The redesign reduced product mass from 99.00 to 88.88 g (10.22%). The software outputs also indicated reductions of 67.16% in carbon footprint, 66.94% in water eutrophication, 67.37% in air acidification, and 67.16% in total energy consumption. The findings demonstrate the value of combining DFMA-informed geometry review with rapid environmental screening to compare alternatives before tooling and prototype production. However, the results are comparative rather than a complete life-cycle assessment because the archived dataset does not report the material database version, transport assumptions, use-phase profile, end-of-life scenario, or uncertainty analysis. The redesign supports resource-efficient product development and contributes to SDG 9 and SDG 12.