The shortage of resource in living environment has been concerned increasingly. At the first design stage, people pay more attention to green product manufacturing based on environment management system, energy conservation, development of cleaner products, and waste and pollution reduction. In this paper, a case study was carried out on optimal design of gear reducer based on the rules of Reduce, Reuse, Recycle, and Remanufacture (4R). The mathematical model was presented for minimizing the volume sum of gear reducer. Genetic algorithm (GA) and MATLAB were applied to optimize the design parameters of gear reducer. The result shows that the volume sum of gear reducer by GA was reduced 1.68% than penalty function. The weight of gear reducer and the amount of raw materials were reduced. A valuable reference of designing real gear reducer was provided, and an approach of promoting development of cycle economy and accelerating the development of national economy were indicated.
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