Supporting the Electric Vehicle REVOLUTION through maximising EV Range and End-of-Life Vehicle Recovery through optimisation of recycled plastics and advanced light materials

Project Information

REVOLUTION

Grant agreement ID: 101006631

DOI

10.3030/101006631

Project closed

EC signature date 18 November 2020

Start date 1 January 2021

End date 30 June 2024

Funded under

• SOCIETAL CHALLENGES - Smart, Green And Integrated Transport

Total cost

€ 5 895 200,32

EU contribution

€ 4 997 912,63

Coordinated by

FARPLAS OTOMOTIV ANONIM SIRKETI
Türkiye

Periodic Reporting for period 2 - REVOLUTION (Supporting the Electric Vehicle REVOLUTION through maximising EV Range and End-of-Life Vehicle Recovery through optimisation of recycled plastics and advanced light materials)

Reporting period: 2022-07-01 to 2024-06-30

Summary of the context and overall objectives of the project

REVOLUTION project aims to overcome the challenges hindering the use of recycled materials, but more broadly, restricting the widespread adoption of circular economy principles in the automotive industry with its cradle-to-cradle design approach.

The Project specifically targets the development of light materials and smart production processes for automotive applications. These will help automotive OEMs to meet the key challenges of End-of-Life Vehicle (ELV) directives and improve electric vehicles' efficiency and range by:
- identifying cost effective ways to implement mass reduction;
- introducing post-consumer recycled plastics (PCR);
- addressing the complicated end-of-life phase and recycling paths.

The Project has developed innovative technologies in automotive injection moulding processes through the use of an AI-based control system to optimize usage of recycled materials and deliver high-quality lighweighted parts. Eco-design approaches have been used to anticipate and minimize environmental impact particularly in relation to materials separation, recycling, recovery and End-of-Life. Specific PCR containing formulations have been developed for a range of thermoplastic types then demonstrated and validated in four automotive components.

REVOLUTION is now even more important following the introduction of the European Commission's End-of-Life Vehicle (ELV) Directive in 2023 with more focus on eco-design and more ambitious targets for reuse and recycling, and use of recycled content materials in manufacturing of vehicles.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The work performed in the REVOLUTION project covers the following:
- Development and optimisation of light plastic materials with >50% recycled content suitable for production of automotive components by industrial melt processing processes (injection, moulding, extrusion, thermoforming)
- Modelling and design of lightweight components
- Development of advanced process control system
- Integration and training of AI/ML control system and production of demonstrator components
- Completion of environmental and societal assessments
- Dissemination & Exploitation of project results

In general, despite some aspects proving more challenging than others, the project progressed well and achieving good results. The main result include:
- design, material formulation and manufacturing process for four ELV components – rear back seat panel, lower rear bumper, B-pillar cover, crash box
- Validation of these components against Stellantis protocols and test methods
- An injection moulding AI control system implemented on the factory floor

For more specific details of the project result please refer to the project website (www.revolution-project.eu) and LinkedIn channel (linkedin.com/in/revolution-project-296435204).

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

REVOLUTION has delivered advances beyond the state of the art for a range of PCR containing thermoplastic material types and production processes for four demonstration vehicle components: Back seat panel, lower rear bumper, B-pillar cover and crash box. Good results from these demonstrators will help facilitate the wider roll-out of PCR containing materials within the automotive industry and adoption of circular approaches.

The project will impact a number of EU directives and policies, three important European industries (Automotive, Plastics, Chemicals) and assist with the transition to green transport and development of a wider circular economy. In particular, REVOLUTION will deliver some key technological solutions towards achieving ELV Directive objectives. Overall the impact of REVOLUTION activities will be environmental gains through the use of eco-design approaches and increased use of recycled materials.

The assessments undertaken during the project following have detailed the following impacts:

Economical
o Improved value chains for all use-cases
o Reduced environmental cost for all use cases
o Reduced energy cost for all use-cases
o Slightly increased final price for all use-cases except B-Pillar

Environmental
o Increased usage of recycled materials comparing to virgin ones and increased metal-replacement potential
o Increased range of EVs
o Increase recyclability rate of all use cases except Crash Box
o Positive contribution to usage of natural resources, ecosystem quality species and climate change

Social
o Positive impact on human health

REVOLUTION logo