Life cycle assessment of an automotive hybrid-filled recycled PET lightweight component

Road transport is a significant contributor to environmental impacts and is responsible for 76% of greenhouse gas emissions of all transport in the EU. With the continued expansion of the automotive sector, a transition towards more sustainable mobility is urgent. Lightweight design is a promising mitigation to reduce the emissions of combustion vehicles during the use phase, or to increase the range of electric vehicles. However, lightweight structures often have a greater environmental impact in other life cycle phases such as production or end of life. In addition, circular economy strategies such as the use of recycled materials promise a further reduction in material-related environmental impact. This study examines the use of a hybrid-filled PET material with recycled content in a lightweight automotive structure with regard to its environmental impact. A holistic life cycle assessment of the innovative multi-material lightweight structure regarding all life cycle phases shows that the environmental impact of the hybrid filled PET component has environmental benefits in the life cycle phases of raw material, production and End-of-Life compared to a steel reference component, this benefit is further increased during the use phase. This material concept is a strategic opportunity to increase the share of recycled plastics in vehicles in the short term, aligning with the European End-of-Life Vehicle Directive from 2023, with a target share of 25% recycled plastics for newly type-approved vehicles from 2030 onwards.