The reduction of overall vehicle weight to minimise fuel consumption and emissions is one of the approaches that the automotive industry is taking to tackle the challenge of designing more sustainable vehicles. However, only addressing the in-use phase of a vehicle will not necessarily lead to the most sustainable solution; to reach this, the carbon footprint of the whole life cycle of the vehicle from raw materials to disposal must be considered. Finding a more sustainable solution to vehicle design can therefore be complex owing to the array of competing design requirements. Furthermore, there are usually manufacturing cost constraints that add to the complexity of the design challenge. This talk will explore design methodology, used by Far-UK Ltd, that can be used to balance the competing factors that lead to better solutions to vehicle design – solutions that are more sustainable whilst being affordable and practical to manufacture.