Green technology integration in product design: A systematic literature review of challenges and approaches

As industries intensify efforts toward carbon neutrality and circular economy transitions, embedding green technologies into product design has become a key strategy for minimizing lifecycle environmental impacts. This review aims to systematically synthesize the current state of research on green technology integration in product design, focusing on identifying key challenges, evaluating proposed solutions, and revealing thematic trends. This systematic review analyzes 531 peer-reviewed articles (2000–2025) from Scopus and Web of Science, applying PRISMA protocols and bibliometric tools. Through a refined manual analysis of 100 core studies, we identify key categories of design challenges and corresponding solution strategies. We developed a challenge–strategy mapping matrix to assess the alignment between barriers and solutions. The results reveal that while tool diversity is increasing, most methods remain focused on late-stage evaluation and offer limited support during early design phases, where key decisions are made. To address this gap, we propose a multi-level analytical framework linking challenges across macro (policy), meso (organization), and micro (design) levels. This review consolidates fragmented knowledge, exposes structural mismatches, and offers actionable insights for developing adaptive, stage-sensitive design tools that support sustainable innovation in complex, resource-constrained contexts.