Integrating environmental assessment into aerospace product development using the VDI 2221 methodology

Abstract This paper investigates how environmental assessment methods can be systematically integrated into an industry-established engineering development process based on the VDI 2221 guideline, as applied in the development of aerospace components at Rolls-Royce Deutschland. Integration points for ex-ante assessment are identified, focusing on the applicability of Life Cycle Assessment (LCA), Screening-LCA, and CAD-integrated Life Cycle-Based Design Assessment (LCBDA). An adapted development process is derived and applied to the conceptual development of a novel lightweight front case structure for a business jet engine. The environmental performance of this design is compared to conventional titanium and magnesium-based alternatives. The case study illustrates how material selection and lightweighting decisions influence environmental impact, particularly in the use phase. The findings demonstrate the feasibility and limitations of integrating environmental assessment into high-technology aerospace development and offer guidance for balancing environmental and technical design criteria under industrial constraints.