Circular Design for automotive engineers

The Need for Circular Design - focus on automotive industry

What you'll learn
- Apply the ISO 59004 R-hierarchy to choose the highest-value circular strategy for any component.
- Implement five core circular design principles: Design for Disassembly, Modularity, Material Selection, Durability, and Maintenance & Repair.
- Calculate Total Cost of Ownership (TCO) comparisons that include recovered value and show the business case for circular options.
- Create practical disassembly, repair and remanufacture specifications that meet <10 min module access and <30 min serviceability targets.
- Specify materials and labeling for high-quality recycling and Digital Product Passport (DPP) requirements.
- Design at least one pilot component roadmap (R2–R5 enabled) with measurable circularity KPIs (MCI, repairability, remanufacturability).
- Identify viable circular business models (PaaS, remanufacturing, parts harvesting, second-life) and estimate revenue impact.
- Prepare compliance-ready documentation for EU ESPR, Right to Repair and EPR obligations relevant to automotive components.

Requirements
- Basic engineering literacy (CAD/PLM familiarity recommended).
- Familiarity with product lifecycle concepts and standard mechanical/electrical design practices.

Description
Automotive sustainability is a hot topic. OEMs and suppliers are under pressure to decarbonize and adopt circularity. Engineers are the start point in this journey. Below is the overview of the course content.

Disclaimer: This course contains the use of artificial intelligencefor audio creation.

Section 1: Introduction & The Need for Circular Design

This section sets the stage by explaining why circular design is critically important for automotive engineersnow, contrasting it with the broken economics of linear design.

Introduction to Circular Design:

Why Circular Design Matters NOW: Covers the key drivers includingRegulatory Pressure(EU ESPR, Right to Repair, EPR),Cost Reality(raw material prices, supply chain disruptions),Market Demand(OEM circularity metrics),Revenue Opportunity(remanufacturing market growth), andCompetitive Advantage(early movers).

The Problem: Linear Design Economics Are Broken: Highlights the shortcomings of the traditional approach (design for lowest upfront cost, ignoring end-of-life). DiscussesHidden Costs(warranty, disposal, fines, material volatility) andLost Revenue(95% material value lost in single-use designs). Emphasizes theEngineer's Rolein long-term value creation.

Section 2: The R-Strategy Hierarchy & Core Principles

This section introduces the fundamental framework for circularity – the R-Strategy Hierarchy – and then dives into the five core design principles that engineers can immediately apply.

Course Content:

The R-Strategy Hierarchy (ISO 59004):

Understanding the differentR-strategiesfrom R0 (Refuse) to R8 (Recycle), ordered by increasing circularity and value retention.

Applying the R-Hierarchy as a Decision Framework: Explains thePriority Order(start at R0, move down only when higher options aren't feasible) and the concept ofValue Retention by Strategy Level. Introduces theDecision Tool: "Why can't I apply R0? R1? R2?"

Core Circular Design Principles:

Core Principle #1: Design for Disassembly (DfD): Defines the target (e.g., <10 min to remove a module), provides anImplementation Checklist(mechanical fasteners, max 3 fastener types, clear pathways, visual indicators, accessible wear components), and anROI Example.

Core Principle #2: Design for Modularity: Sets the goal (component swapping, upgrades), outlinesDesign Rules(group components by lifecycle, standardized interfaces, forward/backward compatibility, independent testing), and discussesBusiness Impact(enables PaaS).

Core Principle #3: Material Selection Strategy: Prioritizes mono-materials, discusses theMaterial Decision Matrix(Durability, Recyclability, Recycled Content, Separability), importance ofLabeling(ISO 11469), andCost Realityof recycled materials.

Core Principle #4: Design for Durability: Establishes theMandate(exceed specs by 30-50%), detailsEngineering Practices(fatigue analysis, environmental testing, designing out failures, corrosion resistance, electronics protection), and presents theBusiness Case(reduced warranty, PaaS enablement).

Core Principle #5: Design for Maintenance & Repair: Defines theRequirement(serviceable part <30 min with standard tools), outlinesImplementationsteps (access panels, avoid proprietary tools, self-diagnostics, digital manuals, spare parts availability), and highlightsRevenue Opportunityfrom aftermarket parts.

Section 3: Circular Business Models, Regulations & Metrics

This section delves into how value is created and captured in a circular economy, the essential regulatory landscape, and the metrics needed to track progress.

Course Content:

Circular Business Models: Where the Money Is:

Model 1: Product-as-a-Service (PaaS): Retaining ownership, selling performance.

Model 2: Remanufacturing: Taking back, restoring, reselling at a percentage of new price.

Model 3: Parts Harvesting: Grading returned units, recombining good modules.

Model 4: Second-Life Applications: Repurposing components (e.g., EV batteries for stationary storage).

Building the Business Case: TCO Analysis: Compares full lifecycle costs, not just unit price, with anExample Calculationdemonstrating significant cost reduction and new revenue streams from circular design.

Regulatory Landscape: What You Must Know:

EU Ecodesign for Sustainable Products Regulation (ESPR): Requirements (durability, repairability scores, recycled content, DPP), Mandates.

Right to Repair Legislation (EU & US states): Requirements (spare parts, tools, manuals), Enforcement.

Extended Producer Responsibility (EPR): The "polluter pays" principle and its cost impact.

ISO 59000 Series: Framework for measuring circular economy (ISO 59004, ISO 59020).

Digital Product Passport (DPP): Your New Design Requirement: Defines what it is (digital twin),Required Data(BOM, manufacturing, lifetime, disassembly, repair history, R-strategies),Implementation(QR/RFID, blockchain/cloud), andBenefits.

Key Circularity Metrics to Track (ISO 59004):

Material Circularity Indicator (MCI): 0-1 score, target >0.6.

Recycled Content %: Minimum targets.

Recyclability Rate %: Target >90% by weight.

Disassembly Time: <10 min for key modules.

Remanufacturability Score.

Repairability Index: Accessibility, documentation, spare parts.

Tool: Integrate into PLM/CAD workflow.

Section 4: Implementation, Overcoming Barriers & Next Steps

The final section equips engineers with practical strategies to implement circular design, address common organizational challenges, and outlines a clear path forward.

Course Content:

Overcoming Barriers: Common Objections & Responses:

Addresses objections like "Circular design costs more upfront," "Customers don't care about sustainability," "No supply chain for recycled materials," and "Remanufacturing cannibalizes new sales," providing data-drivenResponses.

Implementation Roadmap: Your 90-Day Action Plan:

Outlines phases:Baseline Assessment(Week 1-2),Quick Wins(Week 3-4),Pilot Project(Week 5-8),Scale & Integrate(Week 9-12), with specificObjectivesandKey Actionsfor each.

Practical Exercise: R-Strategy Design Review Checklist: A checklist to guide design reviews using ISO 59004 alignment.

Resources & Tools:

Lists relevantISO Standards(59004, 59020, 14001).

MentionsMaterial Databases(GaBi, Ecoinvent, GRANTA MI).

IdentifiesCircularity Assessment Tools(Ellen MacArthur Foundation MCI Calculator, WBCSD Toolkit).

Points toIndustry Networks(MERA, CLEPA).

The Engineer as Change Agent: Emphasizes the significant role of engineers in shaping the automotive industry, creating value, and transforming linear economics.

Key Takeaways: Summarizes the core messages of the lecture.

Your Next Steps: Provides concrete, actionable tasks for engineers (This week, This month, This quarter) to apply their learning.

Who this course is for:
- Automotive design engineers and systems architects responsible for components or subsystems.
- Supplier sustainability leads and product managers who must meet OEM circularity scorecards.
- Remanufacturing and aftermarket managers building takeback and repair programs.
- Technical procurement and standards teams aligning to ESPR, DPP and ISO 59000 series.
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