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DOE OSTI2024

Models implemented in the methodological approach to design the initial STEP first wall contour

The official Spherical Tokamak for Energy Production mission aims to demonstrate the ability to generate net electricity from fusion with the STEP Prototype Power plant. One of the key technological and engineering challenges in fusion power plants is managing the loads on the first wall within acceptable limits. Therefore, the conceptual design development of the STEP Prototype Power plant needs to be based on load estimates derived using legitimate plasma physics assumptions through dynamic and flexible tools. The current design foresees the STEP main chamber first wall to withstand steady-state heat loads of up to ~1 MW/m 2 , excluding critical regions expected to receive higher heat loads such as the baffle regions approaching the divertors. These critical areas will require ad hoc assessments and will be designed with the presence of limiters. This article focuses on the models and methodology adopted for designing the 2-D poloidal contour of the STEP first wall, based on the anticipated charged particle and radiation heat loads during normal operation. Firstly, the models adopted for calculating the charged particle and radiation heat loads are introduced. The first model is validated through benchmarking against the particle tracing code SMARDDA, while the second model is verified by comparing it with data from the MAST-U experiment. Secondly, the model used to design the 2-D first wall contour according to the heat loads is explained. We acknowledge that this preliminary design stage assumes certain simplifications, notably an axisymmetric geometry, for computational efficiency and clarity in presentation. It is understood that subsequent design phases will address the complexities of real-world engineering, including non-axisymmetric effects, transient plasma scenarios, and the impact of disruptions on the first wall design. Finally, an automatic procedure based on these models is presented for defining the 2-D poloidal contour of the STEP first wall to minimize heat loads, taking into account the need to radiate most of the alpha-particle and auxiliary heating power. Here, by providing an overview of the models, methodology, and an automatic procedure, this paper contributes to the design process of the STEP first wall, addressing the engineering challenges associated with fusion power plant development.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Scaling methodologies and similarity analysis for thermal hydraulics test facility development for water-cooled small modular reactor

Small modular reactors (SMRs) represent a promising option for providing clean and sustainable energy due to their potential for enhanced safety, reduced capital costs, and increased siting flexibility. However, new reactor systems require the development and operation of representative scaled-down test facilities to support the verification and validation of system computer codes and models. Here this study reviews the research on scaling methodologies and similarity principles pivotal in developing non-nuclear integral effects test and separate effects test facilities for water-cooled SMRs. The study focuses on a review of the scaling methods, similarity approaches, and possible challenges posed by the unique and compact design features of integral-pressurized water reactor-type SMRs, and their representative test facilities. This study also reviews previous research related to scaling and similarity methodologies and provides insights into design considerations for achieving prototypic conditions in test facilities. The findings and recommendations emphasize the broader impact of appropriate scaling and similarity principles to ensure meaningful and transferable results from non-nuclear test facilities to accelerate the safe and efficient deployment of next-generation water-cooled SMRs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Development and application of two-step uncertainty propagation and sensitivity analysis methodology for fast reactor safety analysis

Uncertainty quantification (UQ) in nuclear reactors for transients is directly linked with safety assessment through the cross-sections uncertainties, provided as a covariance matrix, which are propagated through the reactor system to output of interest pertaining to reactor safety, such as peak temperatures in fuel/clad/coolant. Using a two-step approach, uncertainties are first quantified and propagated from basic input variables (such as reaction cross-sections) to intermediate quantities (such as reactivity feedback coefficients) through lattice level calculations. Uncertainties of intermediate quantities (from the first step) are then propagated through the system transient calculations, in the second step, to obtain uncertainties on reactor safety output parameters of interest. The scope of this work consists of Uncertainty Quantification & Propagation of nuclear data uncertainties that are highly correlated through unprotected transient overpower and unprotected loss of flow to assess their impact on core safety parameters. This two-step approach in the presence of covariance renders the sensitivity analysis very challenging. In fact, usually the sensitivity analysis is restricted to each step, which limits its application since the sensitivities between the system output quantities and the basic input variables are difficult to obtain. Here, in this work, we address this issue by proposing a simple, general methodology to combine the sensitivity indices obtained in each step by assuming the model behavior being linear. For the first step Generalized Perturbation theory based indices are used while in the second step the recently studied Johnson indices. The uncertainty quantification and sensitivity methodologies discussed here are demonstrated on a generic LFR design which is based on the 500 MWth demonstration Lead-cooled fast reactor (DLFR) using oxide fuel, developed by Westinghouse Electric Company (WEC).

42 - ENGINEERING↗

DOE OSTI2026

A Robust Methodology to Elucidate Kinetics of Room Temperature Electrochemical Propane Adsorption on Platinum

Electrocatalytic activation of alkanes can further decarbonize chemical manufacturing by leveraging affordable renewable electricity and readily available shale gas reserves in the United States. Earlier works have identified the unique role of Pt in adsorbing and activating alkanes, like propane, at room temperature in acidic, aqueous electrolytes, revealing spontaneous formation of deeply dehydrogenated propane-derived surface species with an intact C 3 - backbone. Although an adsorption mechanism was hypothesized, it has not been explicitly investigated to date, preventing the quantification of kinetic rate parameters. A robust methodology to investigate and benchmark propane adsorption kinetics on Pt is critical for the rational design of electrocatalysts that exhibit higher selectivity toward desired partially oxidized products. Herein, we analyze an oxidative current transience that appears during the adsorption of propane on Pt in aqueous electrochemical conditions and develop a methodology that elucidates the adsorption mechanism and enables quantification of rate parameters such as order dependences and apparent activation barriers. This method yields an expected first-order dependence with respect to propane concentration at low coverage and reveals a second-order dependence with respect to the concentration of surface active sites. Additionally, the apparent activation barrier for propane adsorption was calculated using an Arrhenius analysis of the current transience under temperature control. The experimentally measured activation barrier of 35 kJ mol –1 is in excellent agreement with the theoretical barrier calculated by density functional theory (DFT). The kinetic analysis was extended, via the use of transition state theory, to extract entropy and enthalpy of activation, yielding consistent results with the proposed two-step adsorption mechanism and DFT calculations. These results demonstrate reliable quantification of kinetic parameters for electrocatalytic activation of C–H bonds in alkanes that can be employed for rational catalyst development for a versatile range of electrocatalytic conditions.

alkane activation↗

DOE OSTI2024

Multitiered computational methodology for extracting three-dimensional rotational diffusion coefficients from x-ray photon correlation spectroscopy data without structural information

X-ray photon correlation spectroscopy (XPCS) is a powerful technique for analyzing particle systems by investigating their dynamics in suspensions across a broad range of temporal and spatial scales. This is done by illuminating samples with coherent x-ray beams and calculating the correlation function of the obtained x-ray scattering images. XPCS is uniquely suited for studying Brownian dynamics, consisting of translational and rotational diffusion. While traditional XPCS image analysis techniques can extract translational diffusion components, they are unable to estimate rotational diffusion coefficients. Here, we introduce a methodology that combines the angular-temporal cross-correlation analysis and a algorithmic framework called Multi-Tiered Estimation for Correlation Spectroscopy in 3D for estimating three-dimensional rotational diffusion coefficients from XPCS images of three-dimensional particle systems. We demonstrate our methodology for extracting rotational diffusion coefficients from XPCS data by applying it to simulated noisy x-ray images of systems of crossing nanotubes and proteins that evolve under translational and rotational Brownian motion for different diffusion rates. Furthermore, our results show that our approach determines rotational diffusion coefficients within a few percent error.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

DEReliction: A Cybersecurity Vulnerability Assessment Methodology for Distributed Energy Resources

With the increasing integration of Distributed Energy Resources (DER) into the electric grid, maintaining grid reliability and resilience requires that these devices remain secure. This paper discusses a cybersecurity vulnerability assessment methodology that incorporates best practices from Sandia National Laboratories, SANS Institute, OWASP Foundation, and other web and Internet of Things (IoT) penetration testing (“pen testing”) programs, courses, and frameworks for assessing the security posture of devices. The methodology involves five sequential steps: (1) Collect Public Information, (2) Extract Hardware Details, (3) Inventory Software Components, (4) Identify Vulnerabilities, and (5) Test Vulnerabilities. Each step uncovers potential weaknesses in both hardware and software components of DER devices, considering adversary tactics, techniques, and procedures (TTPs), and potential attack vectors along the way. The results from the execution of this method on multiple residential- and small commercial-scale photovoltaic (PV) inverters reveled hardware and software vulnerabilities, which highlight the benefit of taking a methodical approach to discover vulnerabilities. While the specific vulnerability details are not shared here, a generalized overview of findings underscore the importance of robust security assessments for DER devices. Adoption of an assessment framework of this kind will identify and mitigate cybersecurity threats and bolster the resilience of DER-integrated electric grids.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

Quality Guidelines for Energy System Studies: Cost Estimation Methodology for NETL Techno-economic Assessments

This Quality Guidelines for Energy System Studies (QGESS) summarizes the methodology employed by the National Energy Technology Laboratory (NETL) in calculating plant costs in its techno-economic studies, such as the Cost and Performance Baseline for Fossil Energy Systems series of reports. It also outlines the approach used to calculate the cost of electricity (COE) or cost of product (COP) metrics by which NETL estimates the impact of technology options. These metrics and a clear understanding of the methodology used are essential in allowing different plant technologies to be compared on a similar basis. These guidelines were initially developed for power producing plants, although they can be applied to a variety of different revenue generating plants (e.g., coal to liquids, syngas generation, hydrogen) by substituting the industrial product quantity for the electrical quantity in the equations. The tables contained in this QGESS have been expanded upon relative to previous versions to include values to assume for several industries.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Developing a Prototype Methodology to Rank CO2-EOR Wells and Assess Their Reuse Potential for Geologic Carbon Sequestration

This study presents a prototype methodology for evaluating the reuse potential of Class II CO₂-enhanced oil recovery (CO₂-EOR) wells as Class VI wells for geologic carbon sequestration. The approach focuses on assessing wellbore construction materials—casing, cement, tubing, and packers—based on U.S. Environmental Protection Agency (EPA) Class VI well conversion guidelines. Utilizing Python scripts and JSON representations, the methodology automates checks on digitized Texas Railroad Commission (TRRC) data to rank wells based on regulatory and integrity criteria. Key factors include casing integrity, cementing techniques, tubing compatibility, and packer selection. Due to limitations in digitized data, manual verification is required for certain sections. Future enhancements include incorporating non-digitized data via web scraping and machine learning. This research provides a practical framework for well owners and regulators, supporting informed decision-making for sustainable CO₂ storage.

carbon sequestration↗

DOE OSTI2025

Construction Methodology Transformation for the Benefit of Workforce Development

Construction is a key economic engine driving both national and global economies. While manual, onsite construction methods dominate the U.S. construction industry, a major shift towards offsite methods has been underway due to its efficiency, speed, and potential cost savings. The workforce necessary for offsite construction growth does not exist in its current form because of the focus on onsite methodologies and the lack of exposure to offsite building methods at all levels of a student’s learning journey. The growth of the U.S. construction industry and competitiveness in an increasingly global construction market over the coming decades can only be supported by a dramatic increase in the use of offsite methods, which requires ramping up workforce training for certain skillsets. The goal of Construction Methodology Transformation for the Benefit of Workforce Development was to understand the opportunities and barriers in both education and industry and to identify best practices for offering curriculum and training to educators, industry, and students that would support skills needed for careers in offsite construction. Our team proposed combining three offsite construction workforce development needs: content development, exposure and training, and job placement - under a single Platform model that would increase experience and career opportunities for students and help match them with potential industry members. Through our proposed solution we expected to see: developed offsite curriculum being utilized by educators and students; an increase in the identification of construction technology and offsite construction methods; an average increase in knowledge gain of at least 25% after participation in pilots; better equipped candidates who are prepared for jobs in offsite construction; and a beta workforce development platform that helps build more pathways for students looking for careers in offsite construction. The two pilots included almost 250 students and resulted in an average knowledge gain of 37 percent. Our research has identified areas of opportunity, for both education and industry to make collaborative training programs more efficient and successful. The chosen techniques for this program are extremely effective when both the school and factory have solid processes and cultures in place to accept students into training programs. This project serves as an important stepping stone to industrywide collaboration to move workforce development for offsite construction forward across the country. With continued collaboration programs like this can provide much needed early exposure and training in offsite construction and we can begin to fill important positions for the future of construction.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2025

Methodology for Determination of Cellulosic Glucans and Hemicellulose Content in a Fuel Ethanol Production Facility (CRADA Final Report)

Develop a single methodology for determination of the total cellulosic glucan, including both cellulose and beta-glucans, along with hemicellulose content in corn kernel fiber which could be utilized by the dry grind corn ethanol production industry to determine the cellulosic converted fraction of the corn kernel fiber. The work will build upon a methodology already described in literature but will specifically focus on a more complete determination of the structural polysaccharides in corn kernel fiber to make it more applicable to the corn ethanol industry.

09 BIOMASS FUELS↗

DOE OSTI2024

Methodology for Evaluating Commercial Energy Code Updates

This document lays out the Department of Energy’s (DOE’s) methodology for evaluating the cost-effectiveness of energy code and standard proposals and editions. The evaluation is applied to new provisions or editions of ANSI/ASHRAE/IES Standard 90.1 and the International Energy Conservation Code. The methodology follows standard lifecycle cost (LCC) economic analysis procedures. A cost-effectiveness evaluation requires three steps: 1) evaluating the energy and energy cost savings of code changes; 2) evaluating the incremental and replacement costs related to the changes; and 3) determining the cost-effectiveness of energy code changes based on those costs and savings over time.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Methodology for Evaluating Energy Savings, Cost-Effectiveness, and Societal Impacts of Commercial Energy Code Changes

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Idaho National Laboratory CY 2024 National Emission Standards for Hazardous Air Pollutants Analysis, Methodology, and Results for Radionuclides

This report documents the methodology and results for calculating the effective dose equivalent (EDE) to the maximally exposed individual (MEI) from atmospheric radionuclide emissions from Idaho National Laboratory (INL) sources in Calendar Year (CY) 2024. The calculations were performed in accordance with requirements in Code of Federal Regulations (CFR), Title 40, “Protection of the Environment,” Part 61, “National Emission Standards for Hazardous Air Pollutants (NESHAPs),” Subpart H, “National Emission Standards for Emissions of Radionuclides Other than Radon from Department of Energy Facilities” (40 CFR 61, Subpart H). UDFs were calculated using the computer model CAP88-PC for unit (1 Ci/yr) emission rates at INL Site facilities and INL in-town (Idaho Falls) facilities and stored in Microsoft Access databases. The UDFs—in this case, mrem/Ci—were then combined with radionuclide-specific release (emission) rates for each facility-specific source to compute doses at predetermined public receptor locations, including the MEI locations. This report contains the dose results and a description of the methodology and tools used to compute the doses.

07 - ISOTOPES AND RADIATION SOURCES↗

DOE OSTI2026

Adaptive Cybersecurity for Distributed Energy Resources (AdCyDER): Online Reinforcement Learning with Stackelberg-Optimized Defenses — Pipeline Architecture, Evaluation Methodology, and Findings from a Synthetic-Data Evaluation

This report documents the design and evaluation of an integrated online-learning pipeline developed within the AdCyDER project for Distributed Energy Resource (DER) cybersecurity. The pipeline couples a Reinforcement Learning (RL) attack classifier — which produces an attack-type probability distribution — with a Stackelberg game-theoretic (GT) defense selector that consumes those distributions alongside SME-encoded priors over (defense, attack) effectiveness pairings and perdefense costs to choose grid-health-preserving defenses. The objective is not attack classification per se but production of distributions that drive effective defense selection through the Stackelberg layer, learned from delayed grid-health feedback rather than labeled attack data. AdCyDER as a whole is broader than the work presented here; this report covers the specific RL/GT loop integration and its evaluation. We present the integrated pipeline (SCADA telemetry with Fronius inverter physics, Suricata IDS, time-windowed aggregation, per-facility LSTM classifier, Stackelberg optimizer, OpenC2 actuators), an experimental campaign of 28 eight-hour iterations across three baseline modes, and a pipeline-ordered diagnostic protocol. The protocol identifies two distinct failure modes within the loop: paired supervised ceilings on the same features establish that the deployed online RL classifier (macro F1 ≈ 0.07) sits at least 4.7× below a same-architecture supervised LSTM (≈ 0.34) and 10–11× below a linear feature-signal ceiling (≈ 0.70–0.79 depending on per-facility isolation), localizing the dominant failure to the training procedure; and the reward signal driving online updates carries weak directional coupling with classifier correctness in the methodology-expected direction (multi-lens convergent: top-decile P(true) records produce more frequent state changes and slightly larger improvements, top-vs-bot Cohen’s 𝑑 ≈ −0.19), but at effect magnitudes too small to drive gradient-based learning at the campaign sample size. The original learning hypothesis is not supported by the data. The primary contributions are the diagnostic methodology — proposed as a transferable falsification protocol for online RL/GT defense pipelines learning from delayed environmental reward — and the open, reproducible experimental infrastructure. We outline reward reformulation as the highest-priority aspirational next step given the underpowered-but-aligned Q6 reading, with hardware-in-the-loop evaluation as the broadest scope-expansion option.

Blakely, Benjamin [Argonne National Laboratory (AN↗

DOE OSTI2026

A Methodology to Evaluate the Grid Reliability Impact of Oscillations Induced by Large Loads

The rapid growth of hyperscale AI data centers is bringing renewed attention to the reliability risk that sustained forced oscillations pose to bulk power systems, with cyclic computational workloads emerging as a new forcing source. Unlike the broadband, stochastic disturbances from traditional industrial loads such as arc furnaces, AI training and inference facilities can inject large active power swings concentrated at specific frequencies over extended durations - characteristics that existing grid planning practices do not account for. While the North American Electric Reliability Corporation (NERC) has recognized this gap and called for system-level studies of large load interconnections, no standardized methodology exists to screen, simulate, and quantify these risks at the planning stage. This report presents the Risk Assessment Tool for Large Load-induced Events (RATLLE), a Python-based, publicly available script suite developed at the Pacific Northwest National Laboratory to evaluate bulk power system reliability risks from data center-induced oscillations. RATLLE implements a three-module workflow: a screening module that identifies vulnerable interconnection locations and excitable system modes; a simulation module that models cyclic data center load behavior using a commercial positive sequence simulation platform; and an analysis module that computes risk metrics and generates interactive visualization dashboards. The risk metrics, formulated around simulation observables, map oscillation impacts to a three-stage severity scale spanning latent equipment fatigue through imminent cascading failure. The methodology is demonstrated on two Western Electricity Coordinating Council (WECC) system models: a publicly available 240-bus reduced representation and a detailed 2031 Heavy Winter planning case. Case studies illustrate that even modest 50 MW forced oscillations at resonant frequencies can produce wide-area power swings, N-1 security constraint violations, and cascading generator trips through protection actions - outcomes that would not occur under normal operating conditions without oscillations present. The results underscore the need for standardized oscillation impact assessment in large load interconnection studies and provide a reproducible, extensible framework for utilities to adopt or customize within their existing planning workflows.

Biswas, Shuchismita↗

DOE OSTI2025

A novel methodology for assessing the hygroscopicity of aerosol filter samples

Abstract. Due to US regulations, concentrations of hygroscopic inorganic sulfate and nitrate have declined in recent years, leading to an increased importance of the hygroscopic nature of organic matter (OM). The hygroscopicity of OM is poorly characterized because only a fraction of the multitude of organic compounds in the atmosphere is readily measured, and there is limited information on their hygroscopic behaviors. Hygroscopicity of aerosol is traditionally measured using a humidified tandem differential mobility analyzer (HTDMA) or electrodynamic balance (EDB). EDB measures water uptake by a single particle. For ambient and chamber studies, HTDMA measurements provide water uptake and particle size information but not chemical composition. To fill this information gap, we developed a novel methodology to assess the water uptake by particles collected on Teflon filters. This method uses the same filter sample for both hygroscopicity measurements and chemical characterization, thereby providing an opportunity to link the measured hygroscopicity with ambient particle composition. To test the method, hygroscopic measurements were conducted in the laboratory for ammonium sulfate, sodium chloride, glucose, and malonic acid, which were collected on 25 mm Teflon filters using an aerosol generator and sampler. Constant-humidity solutions (CHSs), including potassium chloride, barium chloride dihydrate, and potassium sulfate, were employed in a saturated form to maintain the relative humidity (RH) at approximately 84 %, 90 %, and 97 % in small chambers. Our preliminary experiments revealed that, without the pouch, water uptake measurements were not feasible due to rapid water loss during weighing. Additionally, we observed some absorption by the aluminum pouch itself. To account for this, concurrent measurements were conducted for both the loaded and the blank filters at each RH level. Thus, the dry loaded and blank Teflon filters were placed in aluminum pouches with one side open and in RH-controlled chambers for more than 24 h. The wet loaded samples and wet blanks were then weighed using an ultramicrobalance to determine the water uptake by the respective compound and the blank Teflon filter. The net amount of water absorbed by each compound was calculated by subtracting the water uptake of the blank filter from that of the wet loaded filter. Hygroscopic parameters, including the water-to-solute (W / S) ratio, molality, mass fraction solute (mfs), and growth factors (GFs), were calculated from the measurements. The results obtained are consistent with those reported by the Extended Aerosol Inorganics Model (E-AIM) and previous studies utilizing HTDMA and EDB for these compounds, highlighting the accuracy of this new methodology. This new approach enables the hygroscopicity and chemical composition of individual filter samples to be assessed so that in complex mixtures, such as chamber and ambient samples, the total water uptake can be parsed between the inorganic and organic components of the aerosol.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Protocols and methodologies for acquiring and analyzing critical-current versus longitudinal-strain data in Bi 2 Sr 2 CaCu 2 O 8+x wires

Abstract In the literature on Bi 2 Sr 2 CaCu 2 O 8+ x (Bi-2212) superconducting wires, it is evident that measurement protocols for transport critical-current I c versus longitudinal strain ϵ and definitions of the so-called ‘strain limit’ are generally dissimilar. Yet, values obtained for the ‘strain limit’ are frequently assimilated to being those of the irreversible strain limit ϵ irr , regardless of the I c degradation-criterion used to define it. In effect, ϵ irr should correspond specifically to the I c ( ϵ ) irreversibility onset , where crack formation in Bi-2212 filaments presumably starts. Because I c ( ϵ ) degradation remains progressive over a fairly wide strain range beyond ϵ irr , the different I c degradation-criteria in use do not yield to the same result and, thus, are not equivalent from metrology perspective. Indeed, in studying densified samples of a modern Bi-2212 round wire, we found ϵ irr ≈ 0.4% and ϵ 5% ≈ 0.6% ( ϵ 5% being the strain where I c degrades by 5%). In this paper, we outline and suggest I c ( ϵ )-measurement protocols and data-analysis methodologies in the hope to converge the various approaches taken for studying Bi-2212 strain properties and, thus, remove related result discrepancies. A unified approach would enable more objective data comparisons among laboratories and among different Bi-2212 conductors. It would pave the way for more rigorous studies of effects potentially associated with wire design, powder, heat treatments, and other such parameters on the conductor’s strain properties.

protocols↗

DOE OSTI2025

Redefining Design for Remanufacturing: A Practical Methodology for Prioritizing Remanufacturing Design Rules

Products are often discarded when they fail or no longer meet user needs. These outcomes are frequently shaped by early design decisions. While remanufacturing offers a sustainable alternative by restoring products to like‐new condition, its potential is often limited by designs that do not consider remanufacturing from the outset. This research addresses that challenge by introducing a structured Design for Remanufacturing (DfRem) methodology and a CAD‐integrated tool to support real‐time design decisions. The DfRem framework introduces a new primary design function focused on preserving product functionality across its life cycle. It is supported by a fault tree that identifies failure modes that limit remanufacturing potential and a hierarchy of design principles including Prevent, Minimize, Relocate, Restore, and others. Each principle is linked to actionable design rules that help engineers reduce the need for remanufacturing or improve its efficiency when necessary. To operationalize this framework, we developed CAD plugins for Autodesk Inventor and PTC Creo. These tools use a state machine model to present prioritized design rules based on selected failure modes and user input. By embedding DfRem logic directly into widely used CAD environments, the tool enables engineers to make sustainability‐informed decisions without disrupting existing workflows. Furthermore, this approach highlights the critical role of design in enabling circular and resource‐efficient product development, making remanufacturing a more practical and accessible strategy during the early stages of product design.

CAD↗