Automated Design Sustainability Evaluation Framework: a CAD-Integrated Tool for Real-Time Costing and LCA in Automotive Engineering

As the automotive industry faces increasingly rigorous environmental regulations and an approaching obligation for Digital Product Passports (DPPs), incorporating sustainability metrics into the early design phase has become a necessity. Traditionally, Life Cycle Assessment (LCA) and manufacturing cost estimation are performed during or after the design phase using specific methods and tools, resulting in costly iterations and delayed decision-making. This paper introduces a preliminary computational tool that combines 3D CAD and spreadsheet software via VBA integration. The framework automates the generation of an “Extended Bill of Materials” by extracting geometric and manufacturing data directly from CAD models. This tool’s classification logic is a key innovation that intelligently processes CAD features to identify component categories, such as sheet metal, machined parts, or plastic injections. This automated recognition allows the framework to implement specific algorithmic models for the preliminary estimation of production costs and environmental impact indicators. The gap between computer-aided design and sustainability analysis is partially bridged by the tool, enabling engineers to receive immediate feedback on the carbon footprint and recyclability of their designs during the early conceptual stage. Preliminary testing within automotive case study shows a substantial decrease in lead times for technical estimation and improved transparency in design decision-making. This tool represents a pragmatic step toward “Circular Design” paradigms, supporting compliance with future legislative frameworks and fostering the transition toward a circular economy in transportation systems.