Structural color sensors for lifecycle management in circular manufacturing

Circular manufacturing seeks to extend product lifecycles and minimize waste through reuse, remanufacturing, and recycling. A key challenge in this process is effectively monitoring product conditions to optimize maintenance and ensure product longevity. However, many current monitoring systems for circular manufacturing struggle with complexity, cost, and adaptability in dynamic manufacturing environments, limiting their effectiveness. This paper explores the application of structural color-based sensor systems integrated with camera-based monitoring as a cost-effective and efficient solution for monitoring product through mechanical stress, temperatures, or environmental factors throughout the product lifecycle. These sensors change color in response to mechanical stress, temperatures, or environmental factors, providing both qualitative visual indicators and quantitative data through image processing. By converting RGB data into hue values, camera-based monitoring systems enable real-time, scalable, and adaptable solutions for circular manufacturing processes, including lifecycle monitoring, environmental monitoring, and remanufacturing. A conceptual case study on lithium-ion battery disassembly highlights the potential of structural color sensors to enhance precision and sustainability. Integrating these systems supports streamlined decision-making, improved product quality, and waste reduction, contributing to sustainable manufacturing systems aligned with circular economy principles.