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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Reman Co-Design: A Combined Design and Remanufacturing Optimization Framework for the Sustainable Design of High-Value Components

Remanufacturing is a process that returns end-of-life equipment to as-new conditions and offers numerous environmental and economic benefits. To fully capitalize on remanufacturing, its synergistic interactions with design must be fully realized and addressed during the design stage. Although this fact is widely recognized in the literature, most of the current studies focus primarily either on the design or remanufacturing aspects of design for remanufacturing (DfRem). In an effort to offer a more integrated DfRem approach than those reported in the literature, we propose a new combined design and remanufacturing optimization (reman co-design) framework that takes a holistic approach by leveraging the intricate interplay between design and remanufacturing. Here, the aim of this formulation is to identify the optimal decisions that maximize the benefits of remanufacturing throughout the entire lifespan of a product. To showcase the utility of the new formulation, we are using a case study of a hydraulic manifold, (re)manufactured by John Deere. Using this industry example, we compare the results of reman co-design to the ones from a decoupled remanufacturing design approach. Results reveal that remanufacturing benefits are better realized and improved upon when using the developed reman co-design approach.

design for X↗
DOE OSTI2025

Redefining Design for Remanufacturing: A Practical Methodology for Prioritizing Remanufacturing Design Rules

Products are often discarded when they fail or no longer meet user needs. These outcomes are frequently shaped by early design decisions. While remanufacturing offers a sustainable alternative by restoring products to like‐new condition, its potential is often limited by designs that do not consider remanufacturing from the outset. This research addresses that challenge by introducing a structured Design for Remanufacturing (DfRem) methodology and a CAD‐integrated tool to support real‐time design decisions. The DfRem framework introduces a new primary design function focused on preserving product functionality across its life cycle. It is supported by a fault tree that identifies failure modes that limit remanufacturing potential and a hierarchy of design principles including Prevent, Minimize, Relocate, Restore, and others. Each principle is linked to actionable design rules that help engineers reduce the need for remanufacturing or improve its efficiency when necessary. To operationalize this framework, we developed CAD plugins for Autodesk Inventor and PTC Creo. These tools use a state machine model to present prioritized design rules based on selected failure modes and user input. By embedding DfRem logic directly into widely used CAD environments, the tool enables engineers to make sustainability‐informed decisions without disrupting existing workflows. Furthermore, this approach highlights the critical role of design in enabling circular and resource‐efficient product development, making remanufacturing a more practical and accessible strategy during the early stages of product design.

CAD↗
DOE OSTI2025

A Design for Remanufacturing Framework Incorporating Identification, Evaluation, and Validation: A Case Study of Hydraulic Manifold

In recent years, academic researchers and engineers in the industry have widely recognized the necessity of integrating remanufacturing considerations into product design iterations to advance sustainability objectives. Acknowledging the importance of design for remanufacturing (DfRem), efforts were made to develop tools and guidelines that could be implemented in practice. However, such methods largely rely upon experiential insights and qualitative assessments, leaving a gap in the ability to quantitatively assess the economic and environmental impacts of design choices. To bridge this gap, we investigate existing efforts and present a framework for DfRem that integrates established design and remanufacturing practices into a cohesive workflow with quantitative assessments. To demonstrate its efficacy for making practical design changes for remanufacturing, we apply the framework to a hydraulic manifold in a transmission system for heavy-duty tractors. Through this industry-relevant case study, we focus on showcasing the practical utility of our framework. Based on the identified design modifications from remanufacturability analysis, we estimate the reductions in life cycle costs, energy consumption, and emissions. Afterward, the modifications are tested using physical experiments with plans for integration into future iterations of the hydraulic manifold design and production. Here, we anticipate this framework can illustrate the process of remanufacturing that ensures improvements in sustainability while maintaining performance and reliability standards.

design for X↗
DOE OSTI2026

TRIZ-Based Design Improvement for Facilitating Transmission Control Unit Remanufacturing

Design for Remanufacturing (DfRem) centers on enhancing product design and operations to facilitate remanufacturing while increasing both economic and environmental sustainability. DfRem requires a comprehensive understanding of product characteristics, production conditions, and operational constraints. Thus, DfRem requires a systematic methodology to identify and implement alternative designs. Among many critical steps in remanufacturing, disassembly is essential because it directly supports remanufacturing by separation of product components for cleaning, inspection, and other subsequent process steps. This study proposes a TRIZ-based framework to improve product design for disassembly in support of remanufacturing. The framework is applied to a transmission control unit (TCU) case study. The current TCU design prevents remanufacturing due to the sealant-based component joinery, which complicates disassembly and risks damaging the printed circuit board (PCB). After defining technical contradictions for the TCU product design and reviewing the suggested TRIZ principles to solve the conflicts, a cantilever snap-fit design alternative is developed. The economic feasibility of the snap-fit design is assessed by comparing the current and snap-fit design costs for three life cycles. The cost analysis demonstrates that the cost of the snap-fit design remains the same as the current design. Additionally, the snap-fit design offers substantial cost savings for three life cycles compared to the current design. We demonstrate how snap-fit design supports both environmental and economic sustainability.

42 ENGINEERING↗
DOE OSTI2024

Surrogate-assisted optimization under uncertainty for design for remanufacturing considering material price volatility

Remanufacturing is a well-established end-of-life (EOL) strategy that promises significant savings in energy and carbon emissions. However, the current design practices are not remanufacturing-inclusive, i.e., the majority of products are designed for a single life cycle. As a result, potential products that can sustain multiple life cycles are deprived of additional benefits of being designed for remanufacturing, such as reduced material usage, lower cost, and improved environmental impact. Moreover, the uncertainty in design, material selection, and economics are not considered to produce remanufacturable designs. Accordingly, this research proposes a design for remanufacturing (DfRem) framework that accounts for design uncertainty and material price volatility. The framework systematically explores the design space, performs design optimization under uncertainty, followed by topology optimization to provide additional mass savings, and finally, a price volatility analysis for plausible design material choices. The candidate designs are evaluated based on their design mass, material price volatility, failure mode characteristics, carbon footprint, and embodied energy impacts. The proposed framework's utility is demonstrated via the use of an engine cylinder head case study subjected to thermo-mechanical loads along with fatigue and wear failure. Considering grey cast iron and aluminum alloy as the design material choices, it was found that the cast iron design reduced the initial design mass by 6% as opposed to a 5% decrease for aluminum. On the other hand, about 8% area of the cast iron design failed due to fatigue, compared to 3% for aluminum. Here, we further observed that although the aluminum design provided better mechanical performance than the cast iron design, this material was more expensive and volatile in price.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effects of Material Selection on the Remanufacturability of a Swashplate in an Axial Piston Pump

A swashplate is a critical component in an axial piston pump for motion transformation that undergoes cyclic loading. Traditionally, swashplates are not designed to have multiple lives of operation. According to industry experts, a remanufacturability analysis of swashplates suggests that the scrap rate is high. Among the primary reasons for this high scrap rate is insufficient material on the running surface, especially for subtractive recovery. Therefore, the selection of the proper material and its amount plays a significant role in the fatigue behavior, the remanufacturability of the swashplate, as well as its cost. Analyses addressing fatigue life, remanufacturability, and cost of the swashplate were carried out in this paper through a comparative study utilizing various materials. Recommendations on the material selection that balance the failure consequences, remanufacturability, and cost are provided to guide designers in making informed decisions for alternative design options.

42 ENGINEERING↗
DOE OSTI2026

A System-Level Cost Modeling Framework for Design for Remanufacturing: A Case Study of an Agricultural Machine Transmission

Remanufacturing offers significant environmental and economic benefits by restoring end-of-life products to as-new conditions. Although extensive research has been conducted on the topic, the adoption of remanufacturing practices remains limited across various industries. A primary barrier to broader implementation is the substantial upfront investment required, which necessitates reliable cost modeling to justify potential future savings. Most existing models treat components independently and ignore inter-component dependencies. We develop a probabilistic, system-level cost modeling framework that integrates reliability, reusability, and a dependency matrix to capture cascading effects across components over multiple life cycles. Our model identifies those critical components that maximize remanufacturing benefits across a product's many lives. A toy example and an industry case study (John Deere PowrQuad transmission subassembly) illustrate how design alternatives affect cumulative cost. Using a Monte Carlo simulation (MCS) to perform life cycle cost analysis on the system with different design changes, we show the normalized average cost savings after three remanufacturing cycles. Accounting for dependencies meaningfully alters cost projections and ignoring them underestimates accumulated cost by up to 20% in our examples. Furthermore, the results of our study confirm that accounting for component interdependencies is necessary to produce cost estimates that meet industry standards.

Life Cycle Analysis and Design↗
DOE OSTI2024

A novel design optimization framework to sustain remanufacturability

The ever-increasing global carbon emissions have urged the need for environmentally conscious/sustainable product design, for which the design for remanufacturing (DfRem) is one potential approach. DfRem targets at designing products that have multiple life cycles, thus significantly reducing raw material usage, energy consumption, and carbon emissions. In this paper, we develop a three-stage framework that consists of (1) systematic design space exploration and a multi-objective optimization formulation to minimize the likelihood of failure causes (such as fatigue and wear) and environmental footprint, (2) topology optimization to further reduce material usage without significantly affecting the load-carrying capability of the product, and (3) post-topology optimization design verification to ensure the proposed design satisfies all design constraints. The environmental impact can be assessed at varying comprehensiveness levels (e.g., design and manufacturing phase, use phase) and in terms of carbon or GHG emission, energy use, and waste generation. Because the novel design framework predominantly adjusted the geometry, we focused on mass-based change and energy savings due to sustained remanufacturability. The multi-objective optimization formulation in the first step results in a Pareto optimal set of possible design solutions that the designer can use for the second step. Finally, we demonstrate the utility of this framework through a case study of an engine cylinder head subjected to thermo-mechanical loads, where we find that about 5% of the product mass can be conserved with only about a 3% increase in surface area that has a fatigue life less than 10,000 cycles.

42 ENGINEERING↗
DOE OSTI2023

Key Strategies in Industry for Circular Economy : Analysis of Remanufacturing and Beneficial Reuse

Manufacturing, in the effort to be more sustainable, is increasingly focusing on energy efficiency and waste reduction. DOE’s Better Buildings Better Plants Program has a Waste Reduction Network that works with 32 industrial partners to achieve higher material efficiency and reduce waste. United States generates 7.6 Billion Tons of industrial solid waste as estimated by EPA. In a linear economy as the economy grows, so does the waste – increasing strain on resources and the environment. The Circular Economy (CE) model keeps the available resources in circulation for longer period of time easing the burden on the environment. Remanufacturing and (Beneficial) re-use are widely accepted channels in 9R methodology and established pillars of CE. This paper reviews the two key strategies and their adoption in different industrial sectors. It reviews the key barriers faced by manufacturers in implementing these methodologies and discusses the possible solutions to those barriers. The paper also reviews impact of these CE strategies on sustainability, material efficiency and the economic and social benefits. Finally, this paper presents two case studies from DOE’s Better Plants partners – one on remanufacturing of components in heavy vehicles industry and one on beneficial reuse of spent foundry sand, a non-hazardous solid waste, and discusses the project impacts.

Chaudhari, Subodh↗
DOE OSTI2024

Key Strategies in Industry for Circular Economy: Analysis of Remanufacturing and Beneficial Reuse

Manufacturing, in the effort to be more sustainable, is increasingly focusing on energy efficiency and waste reduction. DOE's Better Buildings Better Plants Program has established Waste Reduction Network that works with 32 industrial partners to achieve higher material efficiency and reduce waste. United States generates 7.6 Billion Tons of industrial solid waste as estimated by EPA. In a linear economy as the economy grows, so does the waste – increasing strain on resources and the environment. The Circular Economy (CE) model keeps the available resources in circulation for longer period of time easing the burden on the environment.Remanufacturing and (Beneficial) reuse are widely accepted channels in 9R methodology and established pillars of CE. This chapter reviews the two key strategies and their adoption in different industrial sectors. It reviews the key barriers faced by manufacturers in implementing these methodologies and discusses the possible solutions to those barriers. The chapter also reviews impact of these CE strategies on sustainability, material efficiency and the economic and social benefits. Finally, this chapter presents two case studies from DOE's Better Plants partners – one on remanufacturing of components in heavy vehicles industry and one on beneficial reuse of spent foundry sand, a non-hazardous solid waste, and discusses the project impacts.

Chaudhari, Subodh↗
DOE OSTI2023

A Polymer Degradation and Remanufacturing Experiment in the High School Classroom

Most students enter college without any exposure to polymer science, which leads to the poor understanding and slow implementation of plastic recycling programs in the United States. Here, to address the knowledge gap in chemical recycling, we introduce a 2-part laboratory experiment that was conducted in multiple high schools and public outreach events to demonstrate the depolymerization of PET via aminolysis and the remanufacturing of cleaved PET fragments into a new aramid polymer. Student experiences were evaluated with two postlab assignments.

Hands-on Learning↗
DOE OSTI2024

AI-Driven Crack Detection for Remanufacturing Cylinder Heads Using Deep Learning and Engineering-Informed Data Augmentation

Detecting cracks in cylinder heads traditionally relies on manual inspection, which is time-consuming and susceptible to human error. As an alternative, automated object detection utilizing computer vision and machine learning models has been explored. However, these methods often face challenges due to a lack of sufficiently annotated training data, limited image diversity, and the inherently small size of cracks. Addressing these constraints, this paper introduces a novel automated crack-detection method that enhances data availability through a synthetic data generation technique. Unlike general data augmentation practices, our method involves copying cracks from one location to another, guided by both random and informed engineering decisions about likely crack formations due to cyclic thermomechanical loads. The innovative aspect of our approach lies in the integration of domain-specific engineering knowledge into the synthetic generation process, which substantially improves detection accuracy. We evaluate our method’s effectiveness using two metrics: the F2 score, which emphasizes recall to prioritize detecting all potential cracks, and mean average precision (MAP), a standard measure in object detection. Experimental results demonstrate that, without engineering insights, our method increases the F2 score from 0.40 to 0.65, while maintaining a stable MAP. Incorporating detailed engineering knowledge further enhances the F2 score to 0.70 and improves MAP to 0.57, representing increases of 63% and 43%, respectively. These results confirm that our approach not only mitigates the limitations of traditional data augmentation but also significantly advances the reliability and precision of crack detection in industrial settings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Direct recycling and remanufacturing of anode scraps

With the rapid expansion of Li-ion battery production, significant amounts of electrode scraps that need to be recycled are being produced during cell manufacturing. Anode scrap that comprises critical materials such as graphite and valuable Cu should be recycled and reintegrated into the battery supply chain. This study reports a simple yet efficient water-based recovery process for delaminating anode films from Cu foils through the intercalation of water between the hydrophilic Cu foil and hydrophobic anode coating. Because of the absence of harsh chemicals, the recovered anode films and Cu foils are battery grade and free of damage in terms of physical and chemical properties. This study also demonstrates the reprocessing of those anode films into a new anode that exhibits electrochemical performance similar to that of the pristine anode. We report this environmentally friendly and cost-effective separation technique allows battery manufacturers to directly recycle and reuse their electrode scraps safely and effectively on-site.

25 ENERGY STORAGE↗
DOE OSTI2024

Remanufacturable "Net-Zero Pb" Perovskite Solar Modules

Our introduced a low-cost recycling method for perovskite PV cells which utilize KI salt-based solvents, a more sustainable chemical compared to commonly used chemicals such as DMF, chlorobenzene etc. All steps of the recycling method were demonstrated in detail in publications and presentations of the team. In addition, the techno-economic team demonstrated that the KI-based method is a more promising option compared to other methods investigated in the literature.

14 SOLAR ENERGY↗
DOE OSTI2023

Reliability-informed end-of-use decision making for product sustainability using two-stage stochastic optimization

The concept of circular economy has been diffused in recent decades to promote economic growth that does not add to the burden on natural resource extraction. Re-X options (e.g., reuse, repair, refurbish, remanufacture, recycle) have been gradually adopted in the product development process and optimized to reduce or eliminate waste and pollution. Although manufacturing incorporating Re-X options can be more environmentally friendly, it involves more sources of uncertainty than traditional manufacturing since the end-of-use products can be collected from multiple origins with various quantities and qualities, and the market demand for both new and remanufactured products cannot be forecasted perfectly. Thus, there is a need to optimize the Re-X policy to alleviate the negative impacts of the higher uncertainty. One option is using the reliability information of new products to estimate the end-of-use conditions and applying multi-stage stochastic optimization to capture multiple demand scenarios. This paper develops a two-stage stochastic optimization model to optimize the quality thresholds for reuse, recycling, and remanufacturing options. Our objective is to minimize the total cost, energy consumption, and environmental impact of producing and providing warranty service for a product family. The model employs reliability information of product components to estimate the warranty service cost and the end-of-use conditions of the returned resources. A case study on a general product family is implemented to illustrate the efficacy of the optimization model. Finally, results show that the two-stage optimization can achieve cost and environmental impact reduction for a hybrid manufacturing and remanufacturing process.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Toward a circular economy: zero-waste manufacturing of carbon fiber-reinforced thermoplastic composites

Fiber-reinforced composites are becoming ubiquitous as a way of lightweighting in the wind, aerospace, and automotive industries, but current recycling technologies fall short of a circular economy. In this work, fiber-reinforced composites made of recycled carbon fiber and polyphenylene sulfide were recycled and remanufactured using common processing technologies such as compression and injection molding. An industrially viable size-exclusive sieving technique was used to retain fiber length and reduce variability in the mechanical properties of the remanufactured composites. Fiber length reduction alone could not explain the strength reductions apparent in the composites, which we propose are due to microstructural inhomogeneity as defined by poor dispersion of the fibers. Future recycling efforts must focus on fiber length retention and good dispersion to make composite remanufacturing a viable path toward a circular economy.

36 MATERIALS SCIENCE↗
DOE OSTI2025

You Only Look Once v5 and Multi-Template Matching for Small-Crack Defect Detection on Metal Surfaces

This paper compares the performance of Deep Learning (DL) and multi-template matching (MTM) models for detecting small defects. DL models extract distinguishing features of objects but require a large dataset of images. In contrast, alternative computer vision techniques like MTM need a relatively small dataset. The lack of large datasets for small metal-surface defects has inhibited the adoption of automation in small-defect detection in remanufacturing settings. This motivated this preliminary study to compare template-based approaches, like MTM, with feature-based approaches, such as DL models, for small-defect detection on an initial laboratory and remanufacturing industry dataset. This study used You Only Look Once v5 (YOLOv5) as the DL model and compared its performance against the MTM model for small-crack detection. The findings of our preliminary investigation are as follows: (i) YOLOv5 demonstrated higher performance than MTM in detecting small cracks; (ii) an extra-large variant of YOLOv5 outperformed a small-size variant; (iii) the size and object variety of the data are crucial in achieving robust pre-trained weights for use in transfer learning; and (iv) enhanced image resolution contributes to precise object detection.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗