Modular Electronics Design: What does the Future Hold?

The Future of Modular Electronics Design

How Right to Repair and Sustainability Are Reshaping the Industry

Global e-waste has reached a staggering 62 billion kilograms annually, with less than a quarter of it being recycled properly. That means for every device responsibly disposed of, five more end up in landfills, leaking toxins, wasting valuable materials, and accelerating resource depletion.

For electronics manufacturers, this crisis is not just an environmental issue but an economic and reputational challenge.

A paradigm shift is underway. Modular design is emerging as a powerful enabler of sustainable electronics and a key driver of the right-to-repair movement. By designing devices that can be easily repaired, upgraded, or repurposed, manufacturers are extending product lifecycles, reducing costs, and future-proofing their business models in a rapidly evolving regulatory landscape.

Understanding Modular Electronics Design

Modular electronics design means creating devices built from interchangeable components, each independently replaceable, upgradeable, and recyclable.

Think of it as the LEGO principle applied to electronics: a system where standardised modules fit seamlessly together through standard interfaces.

The modularity spectrum ranges from limited designs (e.g., replaceable batteries) to highly modular systems such as laptops or smartphones, where every component, from the motherboard to the camera, can be swapped independently. The higher the modularity, the greater the sustainability gains, thanks to reduced waste and easier end-of-life disassembly.

However, modularity introduces engineering trade-offs. Thermal management, mechanical durability, and connector reliability must be carefully managed. With modern materials, precision manufacturing, and improved design-for-disassembly principles, these challenges are now increasingly solvable and profitable.

Facilitating Easier Repair Through Modular Design

The global Right to Repair movement is reshaping policy and consumer expectations. In 2024, the European Union adopted new legislation mandating manufacturers to provide repair information, spare parts, and design accessibility. Similar reforms are advancing across the United States and Australia.

In South Africa, there is currently no specific Right to Repair law covering electronics. However, the Consumer Protection Act (2008) ensures consumers can request repairs or replacements for defective goods, and the EPR regulations under the Waste Act (2021) promote end-of-life responsibility.

For manufacturers, modular design aligns perfectly with this global repairability push.

Benefits include:

Targeted component replacement rather than full-device disposal.
User-friendly disassembly using standard tools.
Reduced reliance on specialised service centres.
Enhanced customer trust and loyalty.

The Framework Laptop is a good example of the principle. Each unit ships with a screwdriver, and users can replace parts in minutes. Similarly, Fairphone offers modular smartphones built from ethically sourced materials with five-year software support.

Upgradability: The New Competitive Edge

Modularity is not only about repairs but also about evolution. Imagine upgrading only your device’s camera or processor instead of replacing the entire product. This approach extends lifespan and transforms how consumers interact with technology.

Economic and Strategic Benefits:

Longer product lifecycles lower the cost of ownership.
New revenue streams arise from selling modules as accessories.
Reduced supply chain complexity, since common parts serve multiple products.
Enhanced customer loyalty, as products stay relevant for years.

For manufacturers, this means recurring revenue through module sales and reduced R&D costs via design reuse. For consumers, it means a sustainable way to stay at the cutting edge without the environmental guilt of constant upgrading.

Design for Disassembly and Circular Manufacturing

Sustainability does not stop at repair and upgrade. Modular design also enables efficient recycling and material recovery.

When products are designed for easy disassembly, materials such as copper, aluminium, and rare earth elements can be reclaimed with minimal contamination, thereby improving yield and reducing the need for virgin extraction.

Case studies have shown that modular products can achieve up to 48% faster disassembly times and up to 32% less reliance on virgin materials.

This directly supports the circular economy model, one where materials loop continuously through production, use, and recovery, rather than ending up in landfill.

South Africa’s EPR regulations encourage manufacturers to take lifecycle responsibility, with growing discussions about integrating repair incentives. Designing for disassembly aligns with EPR principles but is not yet a legal requirement in South Africa.

Overcoming Industry Barriers

Despite its promise, modular design is not without hurdles:

Higher upfront design costs and tooling investments.

Potential resistance from established manufacturers focused on short-term profit.

Market perception that modular equals bulkier or less sleek products.

However, these barriers are falling fast. Consumer awareness around sustainability, combined with new policy incentives and pressure from environmentally conscious investors, is rapidly shifting the business case.

Standardisation at both the component and policy level is key. Industry-wide collaboration on modular frameworks (for example, USB-C for charging or modular motherboards) ensures scalability and interoperability. Once standards are in place, modularity becomes not only feasible but economically superior.

The Business Case for Modular Design

The real question is not whether modular design is viable but how fast competitors are adopting it.

Manufacturer Advantages:

Lower development costs via reusable design modules.
Simplified product line management with shared architecture.
New profit models, including modular upgrades and refurbishment programs.
Enhanced ESG performance, improving investor appeal and brand differentiation.

Consumer Benefits:

Lower long-term ownership costs.
Customisable and future-proof products.
Active participation in sustainability, fostering emotional brand connection.

Ultimately, modular design turns sustainability into a profit centre, not a cost. Brands like Framework and Fairphone have already proven that consumers are willing to pay a premium for sustainable, repairable technology provided it is well-designed and performance competitive.

Manufacturers can achieve cost efficiencies and new revenue streams over time through modular reuse and component sales.

Building a Circular Future

The convergence of modular design, right to repair, and sustainable electronics signals more than a design trend. It marks the foundation of a circular economy for technology.

Manufacturers who act now stand to gain:

Competitive differentiation through sustainability.
Lower lifecycle costs and new revenue streams.
Long-term brand resilience amid tightening regulation.

By 2030, modularity is expected to become a mainstream expectation among sustainability-focused electronics brands. Those who lead the transition will not only build better devices but also help shape a future where innovation and sustainability are finally aligned.

FAQs

What is modular electronics design?
It is a design approach where devices are built from replaceable and upgradeable modules, enabling easy repair, customisation, and recycling.
How does modular design support sustainability?
By extending product lifecycles, reducing e-waste, and improving material recovery rates, modularity directly supports the circular economy.
What role does the right to repair play in modular design?
Right to repair laws push manufacturers to make devices easier to fix, aligning perfectly with modular design principles.
Which companies lead in modular innovation?
Framework and Fairphone are pioneers, offering fully modular laptops and smartphones designed for repair and longevity.
Are modular products more expensive to produce?
Initially, yes, but lifecycle savings, customer loyalty, and compliance incentives offset these costs significantly.