Integrating TRL and LCA for Early Sustainable Product Development

Products are often only checked for sustainability at the end of their life cycle—when the design is already complete. Yet, over 80% of environmental impacts are determined during the concept phase. How can development teams change this?

The combination of TRL (Technology Readiness Level) and LCA (Life Cycle Assessment) enables companies to identify and reduce ecological impacts early on. These approaches help use resources more efficiently, comply with regulations, and drive sustainable innovation. According to the U.S. Environmental Protection Agency, integrating LCA early in product development can reveal hidden environmental costs and opportunities for improvement that might otherwise be missed.

Key Takeaways:

• TRL assesses the technological maturity of innovations (from research to market readiness).
• LCA analyzes the environmental impacts across the entire life cycle of a product.
• Combining TRL and LCA: Early ecological assessments and optimizations boost efficiency and sustainability.
• Real-world examples: Automated processes and material reuse significantly reduce the CO₂ footprint.
• Tools and KPIs: Specialized software and metrics such as CO₂ footprint, material efficiency, and recyclability support implementation.

Why this matters: Decisions made in early development phases influence up to 80% of a product’s environmental footprint. With a structured integration of TRL and LCA, companies can operate not only more sustainably but also more economically. As highlighted by the Ellen MacArthur Foundation, early integration of circular economy principles can unlock significant value and resilience for businesses.

TRL and LCA Basics

TRL Framework Explained

Technology Readiness Level (TRL) is a system that evaluates the technological maturity of innovations. Originally developed by NASA and standardized in 1995, it was integrated into the EU’s Horizon 2020 program in 2014. The TRL scale covers the entire process—from basic research to full system integration, providing a common language for stakeholders to assess progress and risks. For instance, the U.S. Department of Defense uses TRL to manage technology risk and investment decisions.

The TRL stages are as follows:

• TRL 1–3: Basic research
• TRL 4–6: Technology development
• TRL 7–9: System integration

Example: A new bio-based packaging material starts at TRL 2 with lab tests on its chemical composition. At TRL 6, a prototype is tested in a real packaging process—including an LCA comparison with conventional plastic. This staged approach ensures that environmental considerations are embedded alongside technical milestones.

LCA Framework Explained

Life Cycle Assessment (LCA) examines the environmental impacts of a product throughout its entire life cycle—from raw material extraction to end-of-life disposal. It helps use resources more efficiently and identify areas for improvement. For example, a study on PLA disposable cups showed that optimizations can achieve improvements of over 82% in environmental performance. According to the ISO 14040/14044 standards, LCA provides a robust framework for comparing products and processes on a consistent basis, making results more credible and actionable.

LCA supports development teams in three key areas:

• Analyzing environmental impacts across the product’s entire life cycle.
• Identifying optimization opportunities early on.
• Targeted improvement of resource efficiency.

The best results are achieved when these approaches are combined with other methods. LCA studies are often based on ISO 14040/14044 or the EU’s PEFCRs (Product Environmental Footprint Category Rules), which facilitates comparability and regulatory recognition. The European Commission’s PEF initiative is increasingly shaping how companies report and benchmark their environmental performance.

Combining TRL and LCA

Linking TRL and LCA enables significant progress, as real-world examples show. A key element of this integration is Life Cycle Gap Analysis (LCGA), which combines ecological assessments, economic analyses, and circular economy strategies. For instance, an optimized recycling process for PLA materials improved ecological efficiency by more than 88% using this approach. Research from ScienceDirect highlights that integrating LCA into TRL stages helps teams identify environmental hotspots and make informed trade-offs early, reducing costly redesigns later.

Methods for Early Sustainability Integration

Impact Testing in Early Phases

The ecological impacts of a product are largely determined by decisions made in the early development phases. Especially during the requirements definition phase, when key product features are set, it makes sense to consider environmental aspects directly. According to a recent study, early-stage LCA can reduce a product’s environmental footprint by up to 30% compared to traditional approaches.

A structured approach to assessment could look like this:

These early insights lay the foundation for close collaboration between different disciplines, ensuring that sustainability is not an afterthought but a core design criterion.

Team Coordination

To effectively address the environmental impacts identified in early phases, good team coordination is essential. A vivid example is the Urban Cubes project from 2020, where product developers, environmental experts, and urban planners worked together on innovative solutions. In addition to teamwork, it is important to integrate circular design from the outset, putting sustainability at the center. As emphasized by Harvard Business Review, cross-functional collaboration accelerates sustainable innovation and ensures that environmental goals are embedded across product development, procurement, and quality assurance.

Circular Design Principles

Thoughtful circular design is one of the key strategies for sustainable products. The following aspects play a role:

Material selection and efficiency:

• Use of recycled or recyclable materials
• Minimizing material waste during production
• Ensuring easy disassembly

Life cycle optimization:

• Designing for long lifespan and easy repair
• Modular designs that make component replacement easier
• Developing take-back systems for reuse

A successful example shows how modular designs and take-back systems can help close material loops and use resources efficiently. The Ellen MacArthur Foundation documents numerous case studies where circular design has led to significant reductions in waste and resource use.

Tools and Measurements

Software and Systems

Combining TRL and LCA requires specialized software that evaluates environmental impacts throughout the entire development process. Current programs offer features tailored to different phases of product development:

A real-world example: Chemical company Eastman uses the LCA automation solution from Sphera to transparently present the environmental profiles of its products and support its sustainability goals (Sphera Case Study).

SMEs can use cost-effective LCA tools like One Click LCA (automated life cycle costing) or industry-specific Excel-based methods. The simplest way may be to bring in an external expert who already has the necessary licenses. For more on available tools, see the EPA’s LCA software guide.

Success Metrics

The integration of sustainability is measured using specific KPIs:

Environmental KPIs:

• CO₂ footprint per product unit
• Material efficiency in production
• Energy consumption over the entire life cycle

Process-related metrics:

• Recyclability of materials used
• Repairability of products
• Resource efficiency in manufacturing

Studies highlight improvements in resource use (see above). These metrics are widely used in German industry and provide valuable insights. According to McKinsey, tracking such KPIs enables companies to identify cost-saving opportunities while meeting regulatory and consumer expectations.

Examples from German Industry

German industry projects show how these metrics are successfully implemented. For example, a project in the glass and ceramics industry combines KPIs with LCA data to assess direct and indirect emissions. Energy efficiency is also analyzed in relation to production volume (Umweltbundesamt).

Sphera’s LCA software, used by over 1,500 experts, offers:

• Scalability for companies of all sizes
• Real-time data analysis
• Integration of supplier data
• Extensive databases for precise assessments

ISO 14040 Overview: Understanding Life Cycle Assessment

Common Challenges and Solutions

Now that we’ve explained the tools for assessment and optimization, let’s look at typical challenges in integration and possible solutions.

Main Integration Barriers

Early consideration of sustainability criteria often brings several hurdles. For example, a Life Cycle Gap Analysis of PLA disposable cups showed that over 82% of sustainability gaps still exist.

The most common problems include:

Solution Approaches

The Fraunhofer IBP has developed the Sustainability Data Science Life Cycle (S-DSLC), an approach that addresses many of these issues. This approach automates sustainability analyses and integrates them directly into business processes (Fraunhofer IBP).

Some key strategies include:

• Use of automated systems for data collection
• Development of dashboards tailored to different user groups
• Integration of sustainability metrics into existing processes

Experience shows that a step-by-step introduction of sustainability aspects is particularly effective. Companies should actively drive the transition to a circular economy and embed eco-efficiency in their daily operations. The World Economic Forum notes that incremental adoption of circular practices often leads to higher long-term success rates.

Conclusion

The methods and challenges presented make one thing clear: Early integration of TRL (Technology Readiness Level) and LCA (Life Cycle Assessment) is crucial for fostering environmentally friendly innovation. Studies show that a product’s ecological footprint is mainly determined in the initial development phases (IPCC).

While there are numerous economic evaluation methods, there is still a lack of equally effective tools for early ecological analysis. This is problematic, as these early phases often have unpredictable environmental impacts. The latest research calls for more robust, user-friendly LCA tools tailored for early-stage design.

A structured approach to integrating sustainability aspects comprises three main phases:

These phases form the foundation for effective complexity management. Especially in the early development stages, it is important to thoroughly assess technical risks and uncertainties. Effective product life cycle monitoring is essential.

For companies developing sustainable products, the following measures are crucial:

• Design development processes to enable informed decisions early on
• Manage complexity through consistent life cycle monitoring
• Integrate LCA tools into all development phases
• Analyze technical risks early and systematically

The continuous integration of TRL and LCA leads to more environmentally friendly products and reduced environmental impact in the long term. Companies should review their development processes to ensure ecological criteria are considered from the idea stage—and define appropriate tools, roles, and KPIs. For further guidance, the ISO 14040/14044 standards and EPA LCA resources offer practical frameworks.

FAQ

The concepts described above are summarized here using practical questions.

Results of TRL-LCA Integration

The integration of TRL (Technology Readiness Level) and LCA (Life Cycle Assessment) improves material usage, shortens development times, and reduces long-term adaptation costs.

For example, construction projects use life cycle cost analyses (LCCA) to decide between renovation and new construction and minimize total costs (U.S. Department of Energy).

Implementation for Small Businesses

Phase 1: Initial Analysis – Focus:

• Identify key environmental aspects
• Use free LCA tools
• Integrate into existing processes

Phase 2: Systematic Implementation – Focus:

• Train the team
• Build a central database for materials and processes
• Introduce sustainability metrics

These steps can also serve as a foundation for scalable application in larger companies. The EPA’s LCA software guide lists free and low-cost tools suitable for small businesses.

Suitable Industries

An example from the automotive industry shows how regulatory requirements and market demands are reinforcing the focus on sustainability.

This method is particularly suitable for the following industries:

The understanding of sustainability varies between companies, with ecological aspects often taking center stage. These examples show how TRL-LCA can pave the way for environmentally friendly product development, positioning organizations to meet both regulatory and market expectations in a rapidly evolving landscape.