Use of end-of-life photovoltaic (PV) modules is increasing rapidly, creating both environmental challenges and opportunities for improved circular design. This study presents a digital twin-driven design framework that supports low-cost recycling and reuse of solar panel components using only basic mechanical and electrical laboratory setups. The approach integrates 3D computer-aided modeling, guided disassembly, and preliminary experimental testing to establish an accessible methodology for sustainable energy equipment design.

A 3D digital twin of a standard PV module is developed using computer-aided design and simulation tools to visualize structural layers, simulate disassembly steps, and assess material separation pathways. Key components, including the aluminum frame, tempered glass, and encapsulating polymers, are evaluated for recyclability using simple mechanical characterization techniques. In parallel, partially functional solar cells are recovered from decommissioned modules, reconnected, and tested in the electrical laboratory to observe voltage–current behavior and basic stability.

The combined digital–physical workflow demonstrates how digital twin technologies can guide sustainable design for disassembly and support circular-economy practices in renewable energy systems. The proposed model is low-cost, replicable, and suitable for educational environments, offering a practical link between digital design, materials engineering, and renewable energy. This early-stage work highlights the potential of digital twins to accelerate PV recycling and extend solar panel lifecycles through intelligent design methodologies.