SuLiCo - Optimierung der CO₂-Bilanz, Ressourceneffizienz und Recyclingfähigkeit von Leichtbauteilen aus Kunststoff durch Entwicklung und Verbreitung eines datenbankgestützten Softwaretools

Abstract

The joint research project SuLiCo – Sustainable Lightweight Construction focused on the development of a database-supported software tool for assessing the environmental and resource performance of plastic and lightweight products. The objective was to provide environmental information at early stages of product development and to support material and design decisions before product concepts are fully specified. User requirements were identified through expert interviews and a survey among associated industrial partners. The results indicated a need for an early, transparent and easy-to-use comparison of material and product alternatives. Particular relevance was assigned to the carbon footprint, recyclability and secondary material content. Based on these requirements, three software modules were defined: a Material Quick-Check for early material screening, a Product LCA module for component-level assessment, and a Benchmark module for comparing two product variants based on a functional unit. The method considers relevant life cycle stages, including raw material supply, manufacturing, use phase, end-of-life and potential benefits from recycling or substitution. A structured database was developed using material, process, energy, end-of-life and credit datasets. Environmental background data were prepared using ecoinvent version 3.12 and the system model “Allocation, cut-off, EN15804”. The software was implemented as a web-based application with server-side processing and a browser-based frontend. The method was plausibilised using selected case studies, including wind turbine rotor blades and an automotive component. The results showed that the tool can process the defined input data, system boundaries and functional units consistently. Overall, SuLiCo provides a basis for integrating environmental aspects into early-stage lightweight product development. Future work should focus on database expansion, validation with real industrial cases and improved communication of assumptions, data quality and uncertainties