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Generative design is revolutionizing the way manufacturers design parts. New design methods with artificial intelligence enable the design of products that use fewer materials and are therefore more eco-friendly. Sports equipment manufacturer Decathlon is partnering with software provider Autodesk to create a new diving fin with a 50% reduced carbon footprint compared to current market standards.
After successfully redesigning a bike fork using Autodesk Fusion’s generative design in 2020, Decathlon and Autodesk have teamed up again to use the “Design & Make” platform to create the diving fin of the future. The next-gen fin is set to be marketed in 2025.
The “React Fin” project aims to utilize technology to reduce its carbon impact by 50% compared to market standards. Made from recycled plastic, this mono-material fin can be recycled without disassembly at the end of its life cycle.
According to Decathlon, the challenge was to design a fin that maintains constant thickness, unlike traditional fins where rigidity decreases from the foot to the tip. But the goal was also to design a product that meets strict eco-design criteria and has a low environmental impact compared to current fin models.
In a press release, Armand Macé, a product engineer at Decathlon who led the design effort for the new fin said:
“Our goal was to create a disruptive product that departs from traditional models and embraces a completely new approach. We decided to start from scratch.”
Decathlon decided to use Autodesk Generative design tools to achieve this. Generative design is a form of AI that allows engineers to quickly generate hundreds or thousands of potential design solutions based on specific constraints.
According to Fikret Kalay, Senior Manager for Autodesk Research’s Manufacturing Industry Futures group that we interviewed last year:
“Generative design is an AI-based design approach that allows designers to input constraints such as points of fixation, loads, and materials. The algorithm then explores an infinite number of design possibilities within these constraints and presents several solutions. The designer then chooses the best solutions and modifies them based on practical considerations such as size, weight, and maximum deformation.”
This process fundamentally changes how products are designed and optimized. It enables faster, smarter, and more importantly, more sustainable manufacturing. In an era where consumers are increasingly aware of the environmental impacts of their purchases, companies like Decathlon have understood they need to integrate sustainability constraints into their manufacturing methods.
For Raphaël Vis, Circularity Project Manager and Designer at Decathlon,
“Generative design has opened unexplored horizons, allowing us to conceive design solutions previously beyond our reach.”
It is not the first time that Decathlon and Autodesk have collaborated. In 2020, the two companies reimagined a racing bike’s design, leveraging advanced design technologies and new internal collaboration processes. The “React Fin” project draws inspiration from this “bike of the future” initiative.
In addition to its reduced weight and environmental impact, the “React Fin” also offers a new aesthetic, said Raphaël Vis:
“We have changed our view of the product. It is no longer just about power or speed but also about lightness, aesthetics, and environmental impact.”
The goal of Decathlon is to adapt to new sporting practices by designing and manufacturing products tailored to athletes’ needs.
We contacted the company and they stated that Decathlon already uses generative design for other products. The company plans to integrate it into all stages of product development. They incorporate 3D printing in all prototyping phases and in manufacturing spare parts to repair their products.
Technology and sustainability are reshaping innovation. According to Autodesk’s 2024 “State of Design & Make” report, business leaders rank AI as a top technology for achieving sustainability, with 78% believing AI will improve their industry and 79% agreeing it will enhance creativity. This joint project between Decathlon and Autodesk exemplifies these findings.
For Jim Heppelmann, ex-CEO of PTC, another software provider, design engineers hold a pivotal role within the company to address these considerations effectively.
“It’s estimated that 80% of a product’s environmental footprint is committed by engineering decisions made.”
For him, companies aiming to reduce the environmental impact of their products face the challenge of making significant changes if they only start addressing it after the product design is completed. Therefore, the initial step should be to focus on sustainability upstream, specifically during the design phase.
Just like Autodesk’s tools, PTC’s Creo generative design software enables to model and optimize parts using less material, without sacrificing strength and durability.
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