Traditional design decisions have been based on a products performance, quality, and price. There is an assumption that the development of products with environmental-conscious characteristics is more cost intensive than traditional design. Critical decisions to the cost for recycling and disposal are done in the early phases of product development and significantly affect environmental performance for the entire product life-cycle. It is difficult to persuade manufacturers to make changes to the product that would improve the environmental impact, especially when changes occur in additional cost or have a negative effect on the performance, functionality or affordability. Therefore it is even more important to have an effective and efficient design development process and the ability address environmental issues as part of it. The purpose of this thesis is to describe various tools and methods, for usage during the design development process, to optimize the use of material, reduce waste and make products more sustainable. Autodesk is represented as supplier for 3D CAD, simulation and analysis software solutions and those will guide us in improving workflows during the product development process. Starting with the challenges in the product development process, the thesis focuses on the design of plastic products and how mold fill simulation and other tools can impact the environmental quality. The topic of optimization for material reduction by using FEA analysis and simulation of energy loss is also discussed.