This paper presents a methodology that incorporates simultaneous consideration of economic and environmental merit during the virtual prototyping phase of electronic product design. A model that allows optimization of a product life cycle, which includes primary assembly, disassembly, and secondary assembly using a mix of new and salvaged components, is described. Optimizing this particular life cycle scenario is important for products that are leased to customers or subject to product take-back laws. Monte Carlo simulation is used to account for uncertainty in the data, and demonstrates that high-level design and process decisions may be made with a few basic metrics and without highly specific data sets for every material and component used in a product. A web-based software tool has been developed that implements this methodology. Index Terms-Design-for-environment, design-to-cost, disassembly, electronics product take-back, end of life, recycling, virtual prototyping. NOMENCLATURE Quantities associated with specific process steps and the entire unit assembly: Buy back fraction Fraction of the primary assembly cost paid to reacquire primary assemblies for recovery (per assembly). Cost Cost of performing a single assembly process step (per unit assembly). Cost Allocated buy back cost (per assembly). Cost Cumulative cost of all preceding assembly and test steps (per unit assembly). Cost Cost of manufacturing the primary assembly (per unit assembly). Cost Cost of performing a single test step (per unit assembly). Fraction returned Fraction of the primary unit assemblies returned for recovery that are salvageable.