Model-Based Systems Engineering for Sustainable Modular Design: Integrating Design, Manufacturing Operations, and Component Functionality

Reducing CO<inf xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</inf> emissions through sustainable lightweight design is a critical focus in automotive engineering, requiring innovative approaches to material selection and design integration. However, traditional methods often fail to balance performance, manufacturability, and sustainability. This paper demonstrates how Model-Based Systems Engineering (MBSE), utilizing SysML, can address these challenges by systematically integrating design, manufacturing operations, and component functionality. The study aims to enhance stakeholder communication and impact analysis within this complex system by using the MagicGrid methodology within an MBSE framework. This approach aims to enhance system understanding, requirements management, traceability, and risk mitigation in the lightweight design of components for CO₂ emission reduction. The results demonstrate that MBSE provides a clearer perspective for stakeholders, allowing them to use it as a descriptive roadmap for design, manufacturability, sustainability metrics, and validation of component functionality. By demonstrating the effectiveness of MBSE in promoting sustainable practices within automotive component design, this approach helps ensure that environmental objectives are met across the system, from design and manufacturing to functionality.