Design for Sustainability by Additive Manufacturing: A Study of PLA-Based Door Handle Redesign

This paper presents the redesign of a door handle as a case study in applying long-life manufacturing (LLM) principles to the furniture sector, utilizing additive manufacturing with polylactic acid (PLA), a biodegradable and sustainable polymer. The primary objective of this study is to explore the potential of PLA-based components to enhance sustainability, repairability, and durability in everyday furniture items. A door handle was chosen as a representative product to demonstrate the feasibility of this approach. The redesign emphasizes the potential for consumers to 3D print and replace parts as needed, thereby reducing waste and extending product life-cycles. To assess the material’s performance, PLA door handles were subjected to degradation tests under UV light exposure and thermal cycles, simulating real-world conditions. The redesigned handles demonstrated a mass reduction of over 50% compared to the original target, while retaining more than 95% of their initial tensile strength after 14 days of UV-B exposure and thermal cycling between 5 °C and 50 °C. The color change remained minimal, particularly for the white-painted samples, indicating satisfactory aesthetic stability. This research contributes to the growing field of sustainable design, highlighting how additive manufacturing can transform the furniture industry by promoting a circular economy through repairable, durable, and eco-friendly solutions.