Concept for Designing Upgradeable Product Architectures in the Context of Upgrade Circular Economy

The predominant linear economy model of manufacturing, characterized by a take-make-dispose logic, is increasingly incompatible with sustainability goals and resource limitations. Transitioning towards a circular economy requires a fundamental redesign of products to extend their functional lifespan and retain value over multiple use cycles. One key enabler is the capability of product architectures to integrate upgrades that improve performance or functionality. However, most existing architectures are not systematically designed for adaptability, which limits their circular potential. This paper introduces a framework for designing upgradeable product architectures in the context of upgrade circular economy. A structured five-step methodology supports early design decisions by (1) synthesizing design strategies such as modularization, interface standardization, and functional decoupling; (2) the assessment of interface flexibility; (3) a forecast of external change variance based on changing market demands and technological disruption; (4) identifying critical components and (5) iteratively applying targeted design strategies to improve upgrade circularity. A quantitative upgradeability score enables transparent comparison of architecture alternatives. The concept follows an iterative, model-based process integrating technical, market-based, and ecological perspectives. It provides a transferable framework for planning upgrades, supporting modular reassembly, and extending product lifecycles, thereby contributing to the practical implementation of upgrade circular economy principles in industrial product development.