To enable a circular economy, remanufacturing is considered a key strategy due to the high level of value retention. However, for short-cycled products, the accelerated obsolescence of conventionally remanufactured products on the secondary market poses challenges to leverage the potential. Cross-Generational Remanufacturing (CG-Reman) has been developed as a new concept in response, which aims to restore used products into the latest generation for sale on the primary market. For its practical success, it is critical to support product engineers in designing products suitably. Hence, in this paper we further explore the overall CG-Reman process with a lifecycle description, derive requirements for the product’s design and conduct a systematic literature review of 209 sources targeting selection, clustering and matching of Design-for-X (DfX) guidelines with the needs for CG-Reman.

The circular economy (CE) seeks to replace traditional linear models by focusing on resource reuse and circulation. However, developing effective CE business strategies is difficult due to complex user behaviors and product flows. Existing scenario analysis tools often rely on survey-based conjoint methods, raising concerns about discrepancies with real purchasing patterns. This study introduces a data-driven simulation approach that employs a consumer preference model and product circulation processes based on actual operational data. Applied to a second-hand PC rental business, our method more accurately reproduces market behavior and reveals that targeting certain customer segments can enhance profitability and resource utilization. These findings underscore the approach’s value as a practical tool for pre-evaluating strategies in CE businesses.

The reprocessing of used products within a circular factory relies on instance-individual design decisions. This requires specific design knowledge (SDK) on relations between embodiment and functional behavior. However, existing approaches do not model SDK in a way that supports product reuse to fulfill the functional requirements of new product generations. This paper presents a hypothesis-based modeling approach on building and structuring qualitative SDK. Drawing on elements of existing product models, the approach yields three outcomes - a function-related structure, design hypotheses, and the assignment of testing strategies. A case study of an angle grinder demonstrates how the approach addresses the requirements of a circular factory by facilitating targeted SDK buildup, ensuring comprehensive documentation, and preparing the quantification of knowledge.

This paper presents a systematic literature review to figure out challenges of integration of used components into new product generations. Reuse of components is an essential strategy of circularity and is becoming highly relevant as resources are limited and sustainability requirements have to be meet across industries. The reuse process was examined from a constructive perspective. It was found that the reuse process is not uniformly defined and that there is a divergent understanding of it. This divergent understanding continues through the Reuse process steps and the added value of using Reuse. Various technical challenges of reuse were identified. These challenges were translated into requirements that are intended to enable reuse for used components. An initial concept for solving the design problem of integrating used components is proposed with the help of these requirements.

The circular economy has long been regarded as a fundamental strategy for achieving sustainable development. Most recently, it has also been acknowledged as an effective approach to crisis response. This study contributes to this nascent literature by introducing a dual hierarchy of 6Rs strategies as an inspiring framework for circular post-disaster recovery and reconstruction, supporting the “Build Back Better” principle through circular initiatives. The key distinction between the proposed hierarchy and the traditional 6Rs framework lies in the two-vector operationalization of each strategy, addressing both past and future considerations. Also, this article examines the case of war-torn Ukraine as one of the most severe man-made disasters. The study explores Ukraine’s potential for circular recovery within the framework of European Union policies in the construction sector.

Sustainability is no longer just a trend for companies, but is now seen as a mandatory measure for the environmentally friendly and responsible use of existing resources. The Digital Product Passport (DPP) is a transformative tool that aims to increase transparency and promote sustainability throughout the product lifecycle. This paper presents the 150% Information List, a comprehensive framework to help companies identify mandatory and optional data for the DPP. Using a systematic literature review, grey literature analysis and interviews with industry stakeholders, the study compiles 148 data points grouped by product relevance, availability and life cycle phase. The findings highlight the flexibility of the list to adapt to different industries and underline its potential to optimise resource use, meet regulatory requirements and drive innovation in product development.

A roadmap for advancing sustainable and circular designs within the automotive industry is proposed. The emphasis is on the critical role of collaborative ecosystems following the increased transparency and traceability underway in regulations. Emerging Digital Product Passports are central means in Europe’s Green Deal and expects to drive transformation of practices in the automotive ecosystem. The study, conducted by researchers in collaboration with a global truck manufacturer, identifies key areas for action, including data quality, stakeholder value, and communication strategies, to facilitate the circular and sustainable transformation. The vision and actions proposed were refined in workshops with automotive suppliers and service providers. By addressing these challenges, the automotive industry can leverage from data accessibility and accelerate its shift towards sustainability.

The importance of the circular economy as an alternative to today’s prevailing linear economy is recognised in both industry and research. Product designers are having a major influence on this transition by adapting the characteristics of physical products in the early phases of the product development process. However, most products follow a linear approach and are far from being circular. This paper aims to identify the challenges that product designers face when designing circular products. Building on a developed understanding of related terms in circular product design, an exploratory literature review is conducted. The results help to gain an overview and understanding of the challenges that need to be addressed. Therefore, further research directions are derived to support the transition from linear to circular products in the long term.

This study examines how second-hand clothing (SHC) store design influences consumer perceptions and purchase behaviour. Based on findings from two studies (study 1: survey, n=268; study 2: experimental, n=90), design strategies were developed informed by Norman’s Emotional Design model. Results show that fresh and floral scents enhance hygiene perception and purchase intention, while attractive visual presentation improves purchase intention, willingness to pay, and quality and hygiene perceptions. While visceral design addresses some consumer concerns, strategies at all three levels are needed to fully improve the SHC shopping experience as they address consumer concerns, build trust, and encourage sustainable purchasing behaviour.

This work is driven by the aim to minimize material waste in the production of structural sheet metal components. Thus, a rule-based decomposition process for multiply connected planar shapes is presented, analyzing the shape’s boundary and skeleton. Based on four cutting rules, shapes are decomposed to particularly extract straight and strut-like parts, allowing high packing densities for a reduction of material waste. Additionally, an alternative shape decomposition scenario is described, aiming for the avoidance of stress hotspots in structural components. In a case study with various shapes, effects on material waste are investigated involving a strip packing problem. Furthermore, effects on mechanical stress are analyzed. The results show potential to reduce material waste, but also disadvantages regarding mechanical stress. Aspects for further consideration are pointed out.

To support the transition towards a circular economy in hospitals, this qualitative study aimed at understanding how the adoption of reusable surgical gown can be facilitated. It investigates design features that enhance usability and promote sustained (re)use. A wearing test identified difficulties in wearing reusable gowns. Data collection included observations of 34 surgeries and a survey completed by 73 respondents. Thematic analysis revealed opportunities to improve usability, such as optimising packaging to speed up donning, a wider neck opening to reduce discomfort, and incorporating ‘tearable’ closures to simplify doffing. Innovation strategies relevant to the users involve thermal regulation, monitoring gown performance, and including reusable gowns in custom procedure tray packaging. These findings are discussed in relation to design adjustments and value-chain partners.

Extending the lifetime of products is one objective of a Circular Economy. The lifetime of a vehicle is limited not only by wear, but also by declining customer satisfaction. Customer satisfaction is related to the different types of quality. Components aim for different types of quality. That is why modularization is seen as a possible enabler to facilitate both durability and adaptability in the vehicle structure. Additionally, extending their lifetime integrates passenger vehicles into a Circular Economy. This paper aims to define classes of components to support the development of a modular structure for passenger vehicles that is suitable for a Circular Economy. It provides four classes based on the relevance of components to customer satisfaction and their expected lifetime. This enables the targeted development of R-strategies for components.

Various methods, such as LCA, LCC, or circularity indicators, are used to integrate sustainability into product development. However, these approaches often require extensive expertise in both processes and sustainability, which is not always available in combination. This paper introduces a framework based on the double diamond model, structured into (1) a preliminary assessment, (2) a collaborative workshop, and (3) a prioritization process. It aims to help engineers identify sustainability improvements without requiring prior expertise. A case study on an industrial digital printing system identified five opportunities for enhancing sustainability. Three measures were validated using LCA and the RPR metric. The study resulted in seven principles for sustainable printer design, with a lightweight door design, reduced number of rivets, and logistical improvements as key outcomes.