Design Parameters for Enhanced Repairability and Remanufacturability of the Electric Front Cross Differential

Abstract

This thesis investigates the remanufacturing potential of the electric front
cross differential (eFXD) within the context of the circular economy (CE)
and the R‑framework. Environmental assessment, mechanical validation and
structured component classification are combined to identify opportunities
and limitations for remanufacturing. The results show that a limited number
of components, the tube housing, coupling housing, drive shaft, and actuator,
account for over 70% of cradle‑to‑gate (CtG) carbon dioxide equivalent
(CO₂e) emissions, making them key leverage points for circular strategies.

The tube housing and coupling housing demonstrate strong potential for
direct reuse, operating primarily in the elastic regime with high safety
margins. In contrast, the drive shaft is fatigue‑driven and requires design
modifications to enable multiple life cycles, with an increase in diameter
identified as the most effective measure.

Structured assessment using the Remanufacturing Potential Index (RemPI),
complemented by engineering evaluation, enabled classification of
components into repair and reuse categories.

Life cycle assessment (LCA) indicates that remanufacturing can reduce total
climate impact by approximately 12% over two product life cycles compared
to a linear production scenario. This reduction is primarily achieved by
avoiding a second full manufacturing phase for selected high‑impact
components, which dominates total emissions in the linear scenario.

Overall, the study highlights the importance of integrating design for
remanufacturing (DfRem) early in product development, addressing life
cycles, load conditions, disassembly, and validation in a system‑level
approach. The eFXD shows promising remanufacturing potential,
particularly at the component level, with performance strongly dependent on
design choices, durability, and system constraints.

Popular Abstract

Can a car component get a second life?

Electric vehicles reduce emissions while driving, but a large share of their climate impact comes
from manufacturing. As the automotive industry shifts towards a more circular approach, this
work explores the remanufacturing potential of a key driveline component and how extending its
lifetime affects total climate impact.

Every year, the transport sector accounts for around 20 percent of global greenhouse gas emissions. At
the same time, automotive components are commonly discarded after use, even though many still have
remaining value. This represents an unnecessary waste of both materials and energy. A familiar
example is discarding a smartphone because its battery performance has worsened, even though the
rest of the device still functions well.

When discussing sustainable transportation, attention often goes to electric motors, batteries and
charging systems. But a large part of an electric vehicle’s climate impact occurs long before it is
driven, during manufacturing. This work investigates the remanufacturing potential of the electric
front cross differential (eFXD) by combining life cycle assessment, mechanical analysis, and an
evaluation of which parts could be reused or repaired.

The results show that environmental impact is highly concentrated in a small number of components.
Just four parts account for more than two thirds of all the emissions from manufacturing the eFXD.
Several components have clear potential for reuse or repair in a remanufacturing context. Components
such as the housings demonstrate strong potential for direct reuse, as they operate within safe limits.
Others, like the drive shaft, wear out over time due to repeated loading. However, the analysis shows
that even small design changes, such as increasing the shaft diameter by 5 percent, can make the
component last through a second lifetime.

At system level, the life cycle assessment reveals that extending the eFXD to two lifetimes, by reusing
selected high‑impact components, reduces total climate impact by about 12 percent compared to
producing two new units.

This is why design for remanufacturing is important. By designing products that are easier to
disassemble, repair, and reuse, it becomes possible to extend component lifetimes, reduce waste, and
lower the environmental impact of electric vehicles. In addition, this work demonstrates how
combining environmental assessment, mechanical analysis, and component‑level evaluation can be
used as a structured approach to identify components with high remanufacturing potential.

Mini Dictionary:

• The eFXD is a driveline component that helps a vehicle transfer power efficiently and
maintain grip on the road.
• Remanufacturing means restoring a used product to a condition comparable to a new one, by
reusing, repairing and replacing selected parts.
• Life cycle assessment (LCA) is a method used to calculate the environmental impact of a
product across its entire life, from production to use and disposal.

• author: Jevdic, David
• supervisor: Fredrik Schultheiss
• organization: Production and Materials Engineering
• course: MMTM01 20261
• year: 2026
• type: H2 - Master's Degree (Two Years)
• subject: Technology and Engineering
• other publication id: LUTMDN/(TMMV-5388)/1-112/2026
• language: English
• id: 9226016
• date added to LUP: 2026-05-11 10:26:45
• date last changed: 2026-05-11 10:26:45