Reverse Engineering Approach for Enhancing ProductCircularity Under Consideration of Ecological and Economic Aspects

The transition from a linear economy to a circular economy requires products to be designed not only for performance and cost, but also for reuse, repair, remanufacturing, and recycling. However, many existing products were not originally developed according to circular economy principles, making their transformation particularly challenging.

A reverse engineering (RE) approach can be used to analyze an existing product and identify the design, material, and manufacturing choices that limit its circularity. Instead of developing a completely new product, the method starts from the current product and examines its entire life cycle, from raw material acquisition and manufacturing to use and end-of-life.

The proposed methodology combines reverse engineering with three quantitative assessment methods: Life Cycle Assessment (LCA) to evaluate environmental impacts, Life Cycle Costing (LCC) to assess economic performance, and Life Cycle Gap Analysis (LCGA) to measure circularity. This combination makes it possible to identify improvements while avoiding solutions that increase environmental impacts or costs.

The approach follows four main phases. First, the existing product and its life cycle are documented and evaluated. Second, a more circular end-of-life strategy is defined. Third, the processes, materials, or design characteristics preventing this objective from being achieved are identified and modified using Design for X (DfX) principles. Finally, the modified product is evaluated again using LCA, LCC, and LCGA.

This methodology therefore creates a link between reverse engineering and circular product design. By considering circularity together with environmental and economic performance, it provides a systematic way to improve existing products and supports the development of more sustainable industrial solutions.

Reference: Zürn, S., Müller, T., & Henning, F. (2026). Reverse Engineering Approach for Enhancing Product Circularity Under Consideration of Ecological and Economic Aspects. Journal of Circular Economy, 4(1), 248–264.