2026 ASEE Annual Conference & Exposition

Modern manufacturing relies on automated systems like CNC machining for its precision, adaptability, and efficiency. However, this focus on operational performance often overlooks critical environmental impacts across a product’s entire life cycle. As a result, environmental considerations, from design and processing to end-of-life, remain inconsistent and context-dependent. The increasing attention to energy consumption, emissions, and material circularity makes it imperative to integrate sustainability thinking into manufacturing education. To address this gap, this study introduces an instructional module designed to incorporate sustainability-informed product design and processing concepts into a manufacturing processes course. Guided by the Engineering for One Planet framework, the module emphasizes systems thinking, material selection, and design-for-environment strategies. A project-based learning activity is developed in which students redesign a clock base and program CNC G-code to explore environmentally conscious design alternatives and resource-efficient toolpath planning. A component to this module is the use of Large Language Models (e.g., ChatGPT) as creative co-design tools, which allows students to brainstorm new design options and reflect on how digital assistance influences their decision-making. Student learning was assessed using pre- and post-course self-reported surveys and qualitative word cloud analyses. Student project outcomes were further analyzed using a cross-impact mapping matrix to identify relationships among life cycle sustainability and different design and processing strategies. Results indicate that integrating sustainability frameworks within hands-on manufacturing and design activities, supported by generative AI tools, enhances students’ ability to connect design and process planning intents with life cycle considerations and fosters systems thinking for tackling sustainability challenges.