Dell Places Modular Design at Centre of Circular PC Strategy
Dell integrates modular design into PCs to tackle e-waste, with replaceable components supporting sustainability goals and extended product lifecycles
The technology industry faces a mounting environmental challenge as global consumption of electronic devices continues to accelerate. Rapid innovation cycles, coupled with limited product lifespans and poor recycling infrastructure, have created an unsustainable pattern of resource extraction, manufacturing and disposal that threatens to undermine the sector’s progress.
The scale of global e-waste presents a significant challenge for technology manufacturers. Each year, more than 60 million tonnes of electronic waste are created according to United Nations figures. This volume has been increasing by more than 2.6 million tonnes annually, putting e-waste production projections at 82 million tonnes by 2030 if current trends continue.
Electronic waste represents the fastest-growing waste stream worldwide, outpacing effective recycling solutions and creating significant environmental hazards. The toxic materials contained in discarded devices – including lead, mercury and flame retardants – can contaminate soil and water supplies when improperly handled, while valuable materials such as gold, copper and rare earth elements are lost when products reach landfill.
Dell Technologies is revolutionising the way computers are designed and built by implementing modular components that users can replace without specialised knowledge. This approach forms part of the company's response to the escalating global e-waste crisis, which now produces more than 62 million tonnes of discarded electronics annually.
Dell’s Concept Luna drives PC industry towards repairability and reuse
The company’s Concept Luna initiative, launched in 2021, has moved from prototype to production with the introduction of modular components in Dell's commercial laptop range. Most significant among these innovations is a USB-C port that attaches with screws instead of solder – a seemingly small change with substantial implications for device longevity.
“Product design dictates how practical it is to reuse and refurbish components or harvest recyclable materials at the end of a device's life,” explains Maria Mohr, Sustainability Lead for the Global Presales Technical Community at Dell Technologies.
For most laptop manufacturers, damaged ports typically necessitate motherboard replacement, a costly repair that often leads to device disposal. Dell’s approach allows individual port replacement, extending device lifespan while reducing the carbon footprint associated with manufacturing new hardware.
The design isn’t limited to ports. Dell has introduced user-replaceable batteries with simplified cable connections and reduced cobalt content. Memory modules, storage drives and even keyboards can now be accessed and replaced by users following QR-coded instructions embedded in the hardware.
These modifications arrive as European regulators implement Right to Repair legislation and as consumers increasingly demand longer-lasting technology. Dell appears to be positioning itself ahead of these pressures rather than reacting to them.
E-waste crisis prompts rethink of technology product lifecycles
World Health Organisation data cited by Dell projects e-waste growth will reach 82 million tonnes by 2030 if current consumption patterns continue. Only about one-fifth of electronics are formally recycled, with the remainder entering landfills or being processed in unregulated conditions.
This situation creates both environmental hazards and economic inefficiency. Valuable metals including gold, silver, copper and rare earth elements worth billions of pounds remain unrecovered, while toxic materials contaminate soil and water supplies.
Dell's sustainability strategy takes an unusual approach by focusing on design as the primary intervention point rather than end-of-life collection alone. While the company operates recycling programmes in more than 80 countries, it views product design as the critical factor in creating a circular economy for technology.
"Sustainability has always been integral to how we operate — woven into our processes, products and the ways we help customers achieve their goals. We take an end-to-end approach to sustainability," says Maria.
The company has set ambitious targets for 2030, including plans to reuse or recycle an equivalent product for every item customers purchase and to use exclusively recycled or renewable materials in packaging.
Dell’s material strategy reduces virgin resource extraction
Material selection represents another pillar of Dell’s sustainability approach. In 2024, the company incorporated 95 million pounds of recycled and renewable materials into its products, reducing dependence on newly extracted resources.
This strategy includes using aluminium produced with renewable energy, which generates substantially fewer carbon emissions than conventional methods. Bioplastics derived from castor oil replace petroleum-based polymers in select components, while recycled steel and copper reduce mining impacts.
The company has developed a closed-loop plastic supply chain that recovers materials from end-of-life products for use in new components. These recovered plastics make up a significant portion of the housing and structural elements in Dell's commercial product lines.
Packaging has undergone a similar transformation. During fiscal year 2024, 96.4 percent of Dell's packaging materials came from recycled, renewable or reused sources. Paper-based materials have replaced foam cushioning, while single-use plastics have been eliminated from much of the company's packaging.
“I’ve often said our sustainability strategy is as simple as ‘integration everywhere,’” notes Cassandra Garber, Chief Sustainability Officer at Dell Technologies. “A perfect example of that in action is the incredible list of circular design examples we can share that span so many aspects of our new AI PCs.”
Balancing technological advancement with environmental responsibility
As the technology industry pushes forward with AI capabilities that demand increased computing power, Dell recognises the tension between innovation and energy consumption. The company has developed frameworks for measuring and reducing the environmental impact of AI implementations while continuing to advance the technology.
Dell’s approach includes power management specifications for infrastructure, cooling systems that reduce energy use and measurement protocols for calculating the environmental return on technology investments.
The company views sustainability as a core business strategy rather than a separate initiative. Environmental metrics now integrate with financial reporting, while procurement processes include impact assessments for supplier selection.
“Sustainability and ESG commitments are now widely recognised as business imperatives that impact everything from supplier decisions to business strategy,” says Michael Dell, Chairman and CEO at Dell Technologies. “At Dell, we are both meeting our goals and helping customers meet theirs.”
This integration extends to product development, where sustainability considerations influence design decisions from inception. The modular approach in Dell’s laptops exemplifies this philosophy – making devices that last longer through repairability while reducing the resources needed for manufacturing.
For the technology industry, which has historically encouraged frequent device replacement, this represents a significant shift in business model. Dell appears to be betting that consumers and enterprise customers will value longevity and repairability alongside traditional metrics of performance and price.
“We don’t have to choose between competitive innovation and being environmentally responsible,” Maria emphasises. “Instead, we can embrace an end-to-end approach to sustainability: where resources are valued, products are designed with sustainable materials and waste is minimised.”