Mold manufacturing for injection molding remains a resource-intensive process with limited analysis on where sustainability actions create the most value. Despite growing awareness, small and medium-sized enterprises (SMEs) often lack structured, evidence-based approaches to prioritize impactful levers. This study introduces a systematic identification and prioritization of sustainability levers across the mold manufacturing value chain. In collaboration with six mold making companies in Germany and Austria, more than 300 potential levers were identified through detailed process analysis and expert workshops. These were consolidated into a set of 97 actionable levers and evaluated by eleven industry experts according to sustainability impact and practical feasibility. To complement the qualitative findings, Product Carbon Footprint (PCF) assessments were conducted on five representative injection molds. The findings revealed major emission hotspots across Scope 1, 2, and 3 categories and enabled a targeted alignment between levers and environmental impact. The results are consolidated into a ranked Catalog of sustainability levers that offers practical guidance for SMEs to implement high-impact levers and improve their sustainability performance. This Catalog, presented in full within the paper, aligns qualitative insights with quantitative emission data to support strategic decision-making. By doing so, the study provides a concrete foundation for mold manufacturers to develop targeted sustainability roadmaps and strengthen their competitiveness in increasingly sustainability-driven markets.
Boos et al. (2026) studied this question.