Design as the Catalyst of Change for Carbon Reduction in Health Technology

 

Introduction

Designing products to align with NHS net zero targets requires careful consideration of its environmental impact across the entire product lifecycle, from manufacturing to use and end-of-life disposal.

Key considerations include adopting circular economy principles, reducing single-use components, prioritising reusability and resource efficiency, undertaking robust carbon footprinting, and aligning with NHS procurement and assessment standards.

Pd-m specialise in product design and sustainability in health technology and provided this guide for the designers working medical device, life science and drug delivery.

 

Context

The National Health Service (NHS) is estimated to be responsible for approximately 5% of the UK’s total carbon emissions, and as a result it created a net zero road map. The roadmap identified that 60% of its emissions were attributed to the supply chain, and so reaching their goal would require bringing suppliers on the journey too. This was a bold and progressive move, with nothing comparable on scale or ambition in any other country.  

 

Scope 1, 2 and 3

Sustainability isn’t binary, but very much a journey of incremental gains. A solid baseline on an organisation's emissions is typically the first step. Understanding Scope 1, 2 & 3 direct and indirect emissions can be daunting. 




The next step is to move into a carbon reduction plan. Usually Scope 1 & 2 are the easiest place to start since the organisation has a greater influence over these. An approach of Eliminate, Reduce, Substitute and Compensate can help form the basis for the reduction strategy. Scope 3 (indirect emissions) makes up a large proportion of emissions and is heavily influenced by the products being manufactured and distributed, leaving huge potential for improvement in this area by design.

 

Measuring the impact of design 

Measuring the environmental impact of design decisions can be incredibly difficult to quantify. A full ISO level Life Cycle Analysis (LCA) can be a significant undertaking in terms of time, cost, and complexity. Whilst this might be useful as a final verification of a product, it doesn’t help designers measure the impact of their decisions dynamically during the development process. 

This is where sustainable design tools such as carbon and circularity calculators have a real benefit. These allow for quick comparisons to be made on factors including materials, onshoring as well as production processes. The data they provide at a component level can build into a product carbon footprint and give indications on energy required from manufacturing to delivery. When these tools are coupled with a wider understanding of sustainable design strategies, it’s possible to make significant improvements to a product carbon footprint, in turn those reduce overall emissions for the business.  

 

Key considerations through the design process

Below is a guide to key considerations designers should make when creating products within health technology. It provides a a summary of as the product progresses from an early Technology Readiness Level of 0 (Opportunity Discovery & Concept Formation) through to Technology Readiness Level 9 (full commercial deployment).


 

Chapter 1: TRL 0-1 Opportunity Discovery & Concept Formation

Classic Product & UCD
Sustainability Lens
Map clinical/user journey
Map material/resource/energy flows in that journey
Stakeholder interviews (patients, clinicians)
Include sustainability champions, waste managers, and procurement in stakeholder discovery
Develop initial value proposition
Frame sustainable value proposition: decarbonisation, waste reduction, alignment with NHS targets
Explore market signals
Understand sustainability drivers: policy (NHS Net Zero), global ESG trends, materials risk
Prioritise product features based on user needs
Prioritise features enabling low-impact formats (e.g., fewer materials, less packaging)
 

Chapter 2: TRL 2 — Technology Concept & Application Formulated

Classic Product & UCD
Sustainability Lens
Define functional requirements
Explore how functionality might drive carbon/material intensity
Initial sketches, CAD, mock-ups
Use concepts to explore product-service models (reuse, refill, modularity)
Early usability testing
Test assumptions around ease of reuse, cleaning, disposal
Build cost models
Model environmental costs (e.g., early carbon estimation using LCA-lite tools)
Evaluate feasibility
Consider lifecycle feasibility: supply chain, cleaning infrastructure, packaging burden
Select core technologies
Include sustainability screening criteria (e.g., ETO sterilisation vs steam, single-use electronics vs modular)
 

Chapter 3: TRL 3 — Proof of Concept

Classic Product & UCD
Sustainability Lens
Build and test working prototype
Assess material and process impact of prototypes
Validate functional performance
Validate early environmental performance (e.g., rough carbon comparison, durability)
Get user feedback
Ask users about sustainability trade-offs and preferences (e.g., reuse vs convenience)
Iterate based on feedback
Run eco-design loops: iterate to reduce footprint, increase reusability
Source test materials
Avoid toxic/low-recyclability materials from the outset
Document learnings
Record environmental assumptions and decisions for future carbon modelling
 

Chapter 4: TRL 4 — Lab Validation of Functional Prototype

Classic Product & UCD
Sustainability Lens
Validate performance in controlled settings
Evaluate sterilisation compatibility, cleanability, material safety
Improve usability, ergonomics
Improve ease of disassembly, repair, recycling
Conduct risk assessments (usability, mechanical)
Add environmental risks: leakage, contamination, embodied emissions
Engage engineers and test houses
Engage sustainability experts, material scientists, LCA practitioners
Refine product specifications
Refine for minimal materials, low-carbon processes, waste compatibility
 

Chapter 5: TRL 5 — Validation in Relevant Environment

Classic Product & UCD
Sustainability Lens
Simulate real-world use scenarios
Simulate full lifecycle (use, reprocessing, transport, disposal)
Pilot testing with users
Pilot sustainability behaviour (reuse systems, disposal protocols)
Finalise packaging format
Assess packaging for recyclability, volume, unnecessary protection
Evaluate safety, usability in context
Evaluate emissions, resource use in operational context
Document lessons for redesign
Identify design-for-circularity improvements
Incorporate feedback from clinicians
Collect feedback from waste handlers, sterilisation units, procurement officers
 

Chapter 6: TRL 6 — Demonstration in Operational Environment

Classic Product & UCD
Sustainability Lens
Full system integration: device, workflow, packaging
Full lifecycle integration: logistics, cleaning, recovery
Update regulatory documentation
Start sustainability documentation (carbon summary, materials audit)
Human factors validation
Usability of any reuse or return processes
Final supply chain review
Map supply chain emissions and explore lower-impact alternatives
Explore IP and commercial strategy
Evaluate business models for reuse/refill/service-based delivery
 

Chapter 7: TRL 7 — System Prototype Demonstration in Operational Environment

Classic Product & UCD
Sustainability Lens
System-level testing across workflows
System-level impact measurement: waste, energy, carbon
Clinical trials or evaluations
Environmental field testing: does the reuse system work in practice?
Confirm user acceptance
Confirm staff engagement with sustainability workflows
Refine manufacturing process
Refine for efficient, low-impact production (e.g., low-temp molding, local suppliers)
Validate performance vs alternatives
Benchmark sustainability vs incumbent or competitor devices
 

Chapter 8: TRL 8 — System Complete and Qualified

Classic Product & UCD
Sustainability Lens
Submit for regulatory approval
Include environmental validation (ISO 14067, PAS 2050 if needed)
Finalise IFU and labelling
Include sustainability handling: disassembly, return, cleaning, recycling
Freeze design and BOM
Lock low-impact, responsible material choices
Prepare for scale-up
Prepare for sustainable scale-up (e.g., waste agreements, transport emissions)
Plan product support and training
Train users on sustainable use and disposal practices
Create sales materials
Build sustainability into commercial pitch (TCO + carbon + compliance)
 

Chapter 9: TRL 9 — Full Commercial Deployment

Classic Product & UCD
Sustainability Lens
Launch device in NHS and/or private markets
Meet NHS Evergreen criteria; align with Net Zero Supplier Roadmap
Monitor user feedback
Monitor environmental performance (carbon, material use, returns)
Post-market surveillance
Post-market environmental monitoring: real vs modelled impact
Establish tech support and service
Support reprocessing, take-back, and waste minimisation services
Develop case studies
Publish carbon reduction or circularity case studies for NHS buyers
Plan product updates and V2
Plan product iteration for greater sustainability over time
 
 

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