Designing for Disassembly

While LED technology has significantly improved in-use energy performance, many LED-based luminaires and modules still pose challenges for recycling due to their compact, integrated design. Organisations increasingly recognise Design for Disassembly (DfD) as a key strategy to reduce waste and support a circular economy.

The Importance of Disassembly in the Circular Economy

Designers often combine metals, plastics, adhesives, optics, and electronic components in tightly packed assemblies. If these cannot be easily separated, valuable materials are lost and recycling becomes inefficient or economically unviable. According to the European Environment Agency, electronic waste is the fastest-growing waste stream in the EU, with less than 40% of e-waste being recycled properly.

The Waste Electrical and Electronic Equipment (WEEE) Directive places obligations on manufacturers to manage the responsible disposal of products and to design with recyclability in mind (UK Government WEEE Guidance).

Designing for disassembly helps to:

• Improve access to components for repair or refurbishment
• Enable easier material separation at end-of-life
• Reduce labour costs associated with disassembly
• Decrease environmental impact and landfill dependency

Practical Approaches to Design for Disassembly

A number of design strategies are emerging as best practice within the lighting sector.

1. Use of Mechanical Fixings Over Adhesives
Where possible, designers are opting for standard mechanical fasteners such as screws, bolts, or clips rather than adhesives or ultrasonic welding. These methods allow products to be disassembled using basic tools, making it easier to separate parts for recycling or servicing. Research by the Ellen MacArthur Foundation highlights the importance of reversible connections in product design.

2. Material Labelling and Transparency
Plastics and composites should be clearly marked with material identification codes in accordance with ISO 11469 or EN 15343. Clear labelling aids sorting and processing in recycling facilities, especially when automated separation systems are involved. It also ensures that material contamination is minimised, improving the yield and quality of recovered materials.

3. Elimination of Irreversible Bonding Methods
Many luminaires and modules rely on adhesives, thermal pastes, or potting compounds for performance and durability. However, these methods often prevent disassembly. Engineers are exploring alternatives such as replaceable thermal interface pads, mechanical clamping, and snap-fit joints as more sustainable options. This is particularly seen where component access is critical.

4. Modular and Upgradable Architecture
Designing products as modular assemblies - where LEDs, drivers, optics, and heat sinks can be replaced or upgraded independently - extends overall product lifespan. Modular design supports both repairability and recyclability, as components can be individually assessed for reuse or disposal. This approach also aligns with international initiatives such as the EU’s EcoDesign Directive, which encourages manufacturers to facilitate repair and recycling.

Industry Application and Collaboration

While these approaches present opportunities, practical implementation in commercial LED lighting still requires careful consideration. Design constraints such as thermal management, ingress protection, form factor and cost all influence how easily a product can be disassembled.

Some manufacturers, including Forge, have begun integrating disassembly principles into their custom LED solutions. However, industry-wide collaboration is essential to establish shared best practices, develop standards, and ensure consistency across the supply chain.

Initiatives such as the Circular Lighting Live event by Recolight and guidance documents from Lighting Europe are encouraging knowledge-sharing in this space.

Conclusion

As sustainability expectations grow, designing for disassembly offers a clear pathway for the lighting industry to reduce its environmental impact. Beyond energy savings during operation, products must now be judged by their entire lifecycle. This includes from material sourcing to end-of-life recovery.

Adopting these principles will help manufacturers meet current and emerging regulations. It also supports broader environmental objectives such as the UK’s Net Zero Strategy and the UN Sustainable Development Goals.

To future-proof product design, disassembly must be embedded from the start - not bolted on at the end.