Robotics and Computer-Integrated Manufacturing 23 (2007) 727–734 Design for adaptability (DFAD)—a new concept for achieving sustainable design Mary E. Kasarda a , Janis P. Terpenny a,b,c,Ã , Dan Inman a , Karl R. Precoda d , John Jelesko e , Asli Sahin c , Jaeil Park f a Department of Mechanical Engineering, Virginia Polytechnic Institute and State University, Blacksburg, VA 24061, USA b Department of Engineering Education, Virginia Tech., 332 Randolph Hall (0128), Blacksburg VA 24061, USA c Industrial and Systems Engineering, Virginia Polytechnic Institute and State University, Blacksburg, VA 24061, USA d Department of Interdisciplinary Studies, Virginia Polytechnic Institute and State University, Blacksburg, VA 24061, USA e Department of Plant Pathology, Physiology, and Weed Science, Virginia Polytechnic Institute and State University, Blacksburg, VA 24061, USA f Industrial and Information Systems Engineering, Ajou University, Suwon, South Korea Abstract This paper discusses the concepts associated with a new methodology, design for adaptation (DFAD), under development for achieving advanced sustainable designs. The DFAD methodology concept is based on the hypothesis that product life ends because a product is unable to adapt to change. A product may be retired for myriad reasons including that it is broken, out of style, or has become inefficient due to technology obsolescence. In these cases, the product was not able to adapt to change—it was unable to self-heal, it could not modify or reconfigure to meet changing fashion needs, or it could not be upgraded, for physical or economic reasons, to utilize new technology. To address these and similar issues, we are developing the DFAD methodology. DFAD is based on classical control theory and products are conceptualized and modeled as dynamic systems with feedback control strategies to respond, or adapt, effectively to changes in product performance criteria. The DFAD concept takes into account that changing performance requirements may be based on physical, cultural, environmental, and/or economic considerations, among others. r 2007 Elsevier Ltd. All rights reserved. Keywords: Sustainable design; Design for adaptability; Engineering design; Dynamic systems 1. Introduction Design researchers and practitioners have made impor- tant advances in sustainable design by developing meth- odologies and tools to examine the economic and environmental impacts of the total life-cycle of a product [1]. Sustainable design efforts often look to the total life cycle costs of a product for opportunities to reduce waste and pollution, including facilitating the reuse, or recycling of the product at the end of its useful life [1–4]. Surprisingly, there is very limited previous work in the area of developing a comprehensive design methodology to design products for extended life which will have a high impact on sustainability goals. To address this critical missing piece, we have developed a new design methodol- ogy, design for adaptation (DFAD), which characterizes a product as a dynamic adaptable system, and models the product as a controllable system with a feedback loop. The premise is that adaptation is a feedback process with inputs, actuators, and control algorithms, and that a product can be designed to respond effectively to changing inputs to increase useful life. The fundamental basis of the DFAD approach is that a product can be designed as a dynamic adaptable system, and as in all adaptable systems, control and feedback can be used to modify system performance. In some cases, this process will involve remanufacture, and in other cases the utilization of self-healing materials and approaches such as a self-tightening bolt developed by Antonious et al. [5] ARTICLE IN PRESS www.elsevier.com/locate/rcim 0736-5845/$ - see front matter r 2007 Elsevier Ltd. All rights reserved. doi:10.1016/j.rcim.2007.02.004 Ã Corresponding author. Department of Mechanical Engineering, Virginia Polytechnic Institute and State University, Blacksburg, VA 24061, USA. Tel.: +1 540 231 9538; fax: +1 540 231 6903. E-mail address: terpenny@vt.edu (J.P. Terpenny).