As the solar industry continues to grow, the accumulation of photovoltaic (PV) module waste highlights the pressing need for more circular and repairable designs. Conventional laminated modules are difficult to disassemble and recycle, which limits both material recovery and component reuse. While avoiding the lamination improves disassembly, it also compromises the module’s mechanical integrity. This trade-off demands a careful redesign to maintain structural requirements without sacrificing key criteria such as repairability, weight, and cost. This study presents a reliability based optimization approach to redesign the PV module while balancing repairability, weight, and cost constraints. A semi-quantitative relative repairability assessment method, tailored specifically for PV modules, was developed to quantify repairability impacts of design changes. Using Robustimzer software, reliability-base optimization was incoporated to account for uncertain scenarios during the life cycle of the product. Finite Element Analysis and prototype verification ensured compliance with IEC61215 mechanical load standards, achieving an optimized design for mass, repairability and costs simultaneously. As a case study, this methodology was applied to a laminate-free module developed by Biosphere Solar, demonstrating how repairability-focused design can be effectively balanced with structural and economic requirements. The proposed approach offers a scalable framework for advancing sustainable design practices in the PV industry.