Exergy-Based Evaluation of Ecodesign Strategies for Recyclable and Disassemblable Plastic Components in Automotive Applications

The automotive sector is the third-largest consumer of plastics in Europe, after packaging and construction, and its demand is expected to grow. Plastic recycling at the end of vehicle life remains low, with 80% of plastics ending up in energy recovery or landfills. Three vehicle models (SEAT Ibiza Gen. IV and SEAT Leon Gen. II and III) with two trim versions (Reference and Formula Racing) were examined to identify the most critical plastic components from an exergy perspective. Ecodesign measures were defined by considering both the disassemblability of vehicle components and their recyclability potential as key criteria to evaluate end-of-life recovery pathways and guide material and design optimization strategies. The proposed methodology classified the measures into three types: (1) substitution of high-exergy plastics with lower-impact alternatives; (2) use of recycled plastics instead of primary materials, with substitution rates depending on the material; and (3) reuse of components in new models, evaluated by disassemblability and end-of-life condition. Results show that Type 1 measures achieved savings up to 70 MJ, mainly in the floor covering and engine compartment insulator, while Type 2 measures provided larger reductions, up to 1.7 GJ, mainly in bumpers and carpets. Type 3 measures showed reuse potential for paddings and insulators but faced limitations in carpets and dashboards. Findings highlight the importance of material selection and implementing disassembly and recycling strategies to reduce the exergy of vehicle plastics.