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Driven by the moral sense of obligation, legislative and social pressures, manufacturers now consider effective part reuse and material recycling at the end of product life at the design stage. It is a key consideration to use joints that can disengage with minimum labor, part damage, and material contamination. This paper extends our previous work on the design of high-stiffness reversible locator-snap system that can disengage nondestructively with localized heat (Shalaby and Saitou, 2006, Optimal Heat-Reversible Snap Joints for Frame-Panel Assembly in Aluminum Space Frame Automotive Bodies," Proceedings of the LCE2006: The 13th CIRP International Conference on Life Cycle Engineering, Leuven, Belgium, May 31-Jun. 2, pp. 411-416; Shalaby and Saitou, 2008, "Design for Disassembly With High-Stiffness, Heat-Reversible Locator-Snap Systems," ASME J. Mech. Des., 130(12), p. 121701) to include (1) modeling for tolerance stack-up and (2) lock-and-key concept to ensure that snaps only disengage when the right procedure is followed. The design problem is posed as an optimization problem to find the locations, numbers, and orientations of locators and snaps, and the locations and sizes of heating areas, to release the snaps with minimum heat, compliance, and tolerance stackup. The motion and structural requirements are considered constraints. Screw theory is employed to precalculate the set of feasible types and orientations of locators and snaps that are examined during optimization. Multi-objective genetic algorithm coupled with structural and thermal finite element analysis is used to solve the optimization problem. The method is applied on two case studies. The Pareto-optimal solutions present alternative designs with different trade-offs between the design objectives

High-Stiffness, Lock-and-Key Heat-Reversible Locator-Snap Systems for the Design for Disassembly