New Tool Turns CAD Files Into Instant Sustainability Reports

CAD (Computer-Aided Design), is the software engineers use to model products before anything gets built. Nearly every manufactured object you can think of, from a car door to a kitchen tap, started out as a CAD file on someone’s screen.

Digi4Circular project has developed a tool called RapidLCA (Rapid Life Cycle Assessment). In simple terms, it examines a CAD file and estimates the environmental cost of that product before any material is cut or shaped. This milestone marks a real shift in how environmental assessment is done. Instead of relying on isolated case studies handled one at a time, the project has moved toward a standardized, integrated, and AI-driven methodology that can be applied consistently across different manufacturing processes.

This work sits within Work Package 3, led by the University of Florence (UNIFI), which focuses on circular product life cycle and environmental impact scenarios. Big thanks to Massimo Delogu, Caterina Antonia Dattilo, Aljon Kociu, and Riccardo Barbieri from UNIFI for their work on this.

Why this matters

Manufacturing decisions carry long-term consequences. Once a design is finalized, much of its environmental footprint is already determined. Waste levels, energy use, and carbon output all trace back to choices made at the design stage.

The challenge has always been timing. Life cycle assessments typically arrive weeks after a design is complete, long after meaningful changes are still possible. RapidLCA aims to close that gap by bringing environmental analysis directly into the design process.

The foundation of the system

The team built three computational models, each dedicated to a specific manufacturing process:

• Die casting, which predicts material consumption, waste, and casting volumes
• Machining, covering milling and turning, which identifies the process involved and calculates the waste material generated
• Sheet metal, which unfolds part geometries to calculate cycle times and energy requirements

More recently, the team introduced artificial intelligence to strengthen these models. An AI Agent now reads CAD and STEP files directly, drawing on language models such as Ollama, Gemma, and ChatGPT to generate a clear description of the part and accelerate the analysis. A smart matching feature also pairs machining operations with standard raw material sizes automatically.

Where the real value lies

The system goes beyond simple calculations. It selects the most suitable casting method on its own, compares raw material volumes against the material actually removed during machining, and proposes design adjustments that could reduce carbon impact. All of this happens from a single uploaded file.

A step toward smarter manufacturing

Designers can now explore different manufacturing scenarios in real time, rather than waiting for a separate environmental assessment later in the process. One upload produces a manufacturing plan, an environmental evaluation, and practical suggestions for improvement.

This work is part of a broader effort across Europe to make manufacturing more resource-efficient and sustainable. To follow the project’s progress or learn more about related work, visit digi4circular.eu