Achieving zero-waste manufacturing in aerospace requires a shift from end-of-pipe waste mitigation toward circular design principles embedded early in product development. This paper presents a practical framework for integrating circularity into aerospace systems through five design pillars: design for modularity and disassembly, material substitution to enhance recyclability, waste segregation and characterization, component-level circularity readiness scoring, and collaborative supplier engagement.
To operationalize this approach, a Circularity Readiness Assessment Tool (CRAT) is developed to evaluate design alternatives against criteria such as disassembly ease, material recyclability, manufacturing waste potential, end-of-life recovery pathways, and supplier take-back mechanisms. The framework supports multi-criteria decision-making by complementing traditional aerospace design drivers including weight, performance, cost, and safety.
The methodology is demonstrated through a case study of an aircraft seating system. Scenario-based analysis indicates that targeted circular design interventions can reduce material waste and lifecycle carbon emissions while maintaining functional and regulatory requirements. Emphasizing practical engineering workflows rather than exhaustive lifecycle modeling, this work provides a scalable foundation for embedding circular design into aerospace product development and advancing zero-waste manufacturing objectives.