Integrating Circularity Micro-Indicators into Automotive Product Development to Evaluate Environmental Trade-Offs and Guide Sustainable Design Decisions

This study explores the integration of circular design principles into automotive product development, focusing on the environmental implications of design decisions related to geometry, material selection, and assembly methods. A case study approach was used to iteratively redesign a plastic automotive component, incorporating structural reinforcements and glass fiber (GF) to enhance performance. While these changes improved mechanical properties, they negatively impacted recyclability due to increased material heterogeneity and irreversible assembly using ultrasonic welding. Circularity performance was evaluated using the Recycling Desirability Index (RDI), Material Circularity Indicator (MCI), and circular design guidelines (CDGs). Despite achieving 20% recycled content, recyclability remained limited. Alternative design strategies—such as eliminating GF, replacing welding with mechanical fasteners, and enabling take-back systems—led to significant improvements in circularity scores. Notably, MCI analysis indicated that energy recovery pathways offered better circularity outcomes than landfilling. The findings highlight the importance of early-stage material standardization and assembly planning to enhance end-of-life recovery. This study underscores the environmental trade-offs inherent in current automotive design practices and calls for stronger collaboration between engineers, designers, and sustainability experts to align product development with circular economy goals. Findings emphasize the need for systemic changes in product development processes and industrial mindsets, including overcoming resistance to design modifications and fostering cross-departmental collaboration, to effectively implement circular economy principles in the automotive sector.