A comprehensive circular design framework for graphene-enhanced industrial systems: cross-sectoral methodology and multi-criteria evaluation

This study introduces a novel integrated circular design framework that embeds different methodologies, including eco-design strategies, material selection strategies, design for assembly/disassembly, design for recycling, and multi-parameter engineering optimisation, into the earliest stages of development across 11 industrial use cases (UCs). By linking functional lightweighting, design and advanced graphene-related material (GRM)-based multifunctional (GRM-bM) solutions in a unified assessment approach, a demonstration is presented of how qualitative and cross-sector convergence can deliver high-performance products with enhanced recyclability and reduced environmental burden without relying on post hoc LCA. The novelty of this work lies not only in the conceptual advancement of a circular design framework but also in its practical implementation within operational and industrial environments involving complex graphene and GRM-bM systems. This work presents a scalable approach for integrating sustainability into material-intensive systems, from concept to pre-production. Technical and environmental specifications of the UCs, encompassing the automotive, aerospace, water treatment, hydrogen storage, and energy generation sectors, have been considered. A conceptual study has provided a realistic manufacturing scenario and cost analysis, ensuring the feasibility and practicality of the proposed solutions. Furthermore, eco-design concepts are presented to optimise advanced graphene and GRM-bM, feasibility, manufacturing technologies, and recyclability. In alignment with the United Nations Sustainable Development Goals (UN-SDG), this work contributes to delivering graphene-enabled components that maintain mechanical integrity, cut mass by up to 22 %, and achieve projected recyclability above 90 %. In comparison, conceptual manufacturing studies indicate a 20 % energy-saving and 10 % cost reduction. Collectively, these results demonstrate a transferable, scale-ready pathway to high-performance materials that meet the EU Green Deal and UN-SDG ambitions.