Electronic waste, or e-waste, has become one of the fastest-growing waste streams in the world. In 2022, 62 million metric tons were generated equivalent to 7.8 kg per person and only 22.3% of it was formally recycled, according to the Global E-Waste Monitor 2024, published by the UN and UNITAR.
This figure not only highlights the environmental impact of our devices but also underscores the urgency to shift from a linear “extract‑use‑dispose” model toward a circular one, where hardware follows a more intelligent and sustainable lifecycle.
The circular design approach applied to hardware is based on three essential pillars: reuse, recycling, and redesign. This transformation seeks not only to reduce waste but also to create economic value, foster innovation, and make our technology supply chains more resilient.
What is circular design applied to hardware?
Circular design is an approach that prioritizes resource conservation, closed loops, and minimizing environmental impact from the product design phase.
Rather than accepting that devices will be discarded after a few years of use, this approach proposes:
- Designing modular and easily disassemblable components
- Using recyclable, biodegradable or plant‑based materials
- Facilitating repairs, upgrades and refurbishments
- Promoting circular business models such as leasing or hardware‑as‑a‑service
- Implementing more sustainable and traceable supply chains
This model benefits not only the planet, but also users and businesses by reducing long‑term costs, diversifying revenue streams, and meeting growing demand for responsible products.
The urgency of change: alarming figures
The trend is clear: between 2010 and 2022, e-waste generation nearly doubled, while formal recycling increased only slightly. Every year, billions of dollars are wasted in valuable materials such as gold, silver, copper, and palladium contained in discarded hardware. For example, in 2022 more than USD 15 billion worth of recoverable gold was lost in electronic devices.
Human costs are also high: much of this e‑waste ends up in informal dumps in developing countries, where it is handled without safety measures, harming the health of vulnerable communities exposed to lead, mercury, and dioxins.
Reuse: giving hardware a second life
One of the most effective strategies in circular design is reuse and remanufacturing. This involves extending device lifespan through refurbishment, repair, or remanufacture.
Real examples:
- Circular Computing remanufactures HP, Dell and Lenovo laptops with BSI Kitemark certification. Each device avoids 315 kg of CO₂, saves 190.000 litres of water, and preserves 1.200 kg of natural resources. In Ireland, they will supply 60.000 remanufactured laptops to the public sector, avoiding millions in emissions and conserving tons of materials.
- Back Market created a global marketplace for refurbished devices, offering guaranteed products that compete with new ones in quality and performance.
- In Colombia, the program Computadores para Educar refurbishes hardware and distributes it in rural areas, reducing the digital divide.
Advanced recycling: urban mining and value recovery
When a device can no longer be reused, advanced recycling comes into play, focusing on extracting valuable materials without pollution.
Example:
- The Royal Mint in the UK built a pioneering plant that processes 4.000 tonnes of circuit boards per year, recovering half a kilogram of gold, 1.000 kg of copper and 50 kg of palladium all at room temperature and without incineration. This practice, known as urban mining, transforms waste into local raw materials, reducing reliance on traditional mining.
Redesign: sustainability from the start
Redesigning hardware for the circular economy means fully reimagining device structure and materials, prioritizing disassemblability and repairability.
Real examples:
- Framework Laptop: a modular laptop that allows easy part replacement or upgrades without special tools.
- Fairphone: a smartphone designed for user repair, with interchangeable parts and fair‑trade materials.
- Dell and ASUS already design devices with easily separable parts and use recycled plastics for casings.
The 5 trends driving circular design in 2025
- Design for disassemblability: more manufacturers are prioritizing devices that can be opened, disassembled and repaired easily, complying with “right to repair” regulations.
Example
iPhone 14 uses screws and a modular structure enabling easy screen and battery replacement.
- Smart, sustainable materials: the use of recyclable materials, bioplastics, or plant‑based composites reduces device environmental impact.
Example
Companies using starch‑based bioplastics for keyboards or casing.
- Industrial symbiosis: collaboration between industries to reuse by‑products and waste.
Example
A cable manufacturer shares copper surplus with a circuit board producer.
- Traceability and transparency: Blockchain and digital twins allow tracking of origin and recyclability of each component.
Example
Circularise uses blockchain to trace the full lifecycle of chips and batteries.
- Circular business models: instead of selling devices, companies opt to lease them, retaining responsibility for recycling and refurbishment.
Example
Philips offers “lighting as a service,” retaining equipment ownership and managing circular renewal.
Current barriers and challenges
Although the circular model is advancing, it still faces significant obstacles:
Legacy design: many current devices aren’t designed to be disassembled or repaired.
Lack of regulation: in many countries, manufacturers are not legally required to manage the full product lifecycle.
Initial costs: redesigning devices or establishing advanced recycling plants requires substantial investment.
Consumer culture: many consumers still prioritize new over repairable products.
Benefits of adopting a circular approach
- Environmental: drastically reduced waste generation, CO₂ emissions, and extraction of critical materials.
- Economic: recovery of valuable materials, production cost savings, and creation of new jobs (up to 80,000 in the UK alone if VAT on refurbished products is removed).
- Social: more equitable access to technology via refurbished devices; reduced risk in vulnerable communities.
- Reputational: companies adopting circular models build stronger, more trusted brands.
What can companies do?
Design for circularity from the outset: use recyclable materials and modular structures.
Extend product lifespan: offer maintenance, updates and refurbishment options.
Create recovery networks: partner with plants like Royal Mint or tech startups to close the loop.
Adopt traceability technologies: such as IoT, blockchain or AI to track components and optimize reuse.
Measure impact: use metrics like the Circularity Material Index (CTI) to assess sustainable performance.
Future outlook
Without action, e-waste generation could reach 82 million tonnes by 2030, with recycling rates dropping to 20%. However, raising formal recycling to 60% would generate net benefits exceeding USD 38 billion annually, including health improvements, emissions reductions, and green job creation.
Integrating AI, digital twins, modular design and new business models will be key to making circular design the new standard.
Conclusion
From e‑waste to circular design is a path full of challenges, but also opportunities. Reuse, recycling and redesign are essential pillars for a more responsible and innovative tech industry. Cases like Royal Mint, Circular Computing, Dell, ASUS and Fairphone show it is possible to align profitability with sustainability.
Switching to circular design in hardware is no longer an optional add-on, it’s a necessary response to today’s challenges. Companies that adopt this approach not only reduce their environmental impact but also position themselves more effectively for a landscape where regulations, social pressure, and competition are raising the bar for sustainability.
