Browse Topic: Circular economy

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Automated Design Sustainability Evaluation Framework: A CAD-Integrated Tool for Real-Time Costing and LCA in Automotive Engineering2026-37-00446/9/2026
As the automotive industry faces increasingly rigorous environmental regulations and an approaching obligation for Digital Product Passports (DPPs), incorporating sustainability metrics into the early design phase has become a necessity. Traditionally, Life Cycle Assessment (LCA) and manufacturing cost estimation are performed during or after the design phase using specific methods and tools, resulting in costly iterations and delayed decision-making. This paper introduces a preliminary computational tool that combines 3D CAD and spreadsheet software via VBA integration. The framework automates the generation of an “Extended Bill of Materials” by extracting geometric and manufacturing data directly from CAD models. This tool’s classification logic is a key innovation that intelligently processes CAD features to identify component categories, such as sheet metal, machined parts, or plastic injections. This automated recognition allows the framework to implement specific algorithmic models for the preliminary estimation of production costs and environmental impact indicators. The gap between computer-aided design and sustainability analysis is partially bridged by the tool, enabling engineers to receive immediate feedback on the carbon footprint and recyclability of their designs during the early conceptual stage. Preliminary testing within automotive case studies shows a substantial decrease in lead times for technical estimation. Specifically, analysis time was reduced by at least 90%, with subsystems processed in under 10 minutes, a significant improvement over traditional manual calculations. This tool represents a pragmatic step toward “Circular Design” paradigms, supporting compliance with future legislative frameworks and fostering the transition toward a circular economy in transportation systems.
Guadagno, Maurizio, Cecconi, Leonardo, Berzi, Lorenzo, Delogu, Massimo
Enabling Circularity in the Aerospace Maintenance Ecosystem through Generative-AI Driven Back-to-Birth Traceability of Life-Limited Engine Parts2026-26-07196/1/2026
Circular-economy principles are increasingly central to aerospace sustainability strategies, aiming to extend asset life, improve asset valuations, and enhance benefits to stakeholders in the part ownership and maintenance lifecycle. In aircraft engines, achieving circularity hinges on safe reuse, repair, and recirculation of high-value components. Life-Limited Parts (LLPs) are among the most critical in this context, but their reuse is strictly contingent on complete Back-to-Birth (BtB) traceability. Any gap in BtB records—often due to fragmented data across multiple airline operators, shop visits, document formats, and time expanse—renders otherwise serviceable LLPs unusable, leading to premature scrappage and lost circular value. This paper presents a Generative AI (GenAI)-driven methodology to reconstruct and validate complete LLP BtB histories from heterogeneous, unstructured, and legacy maintenance datasets. By combining aerospace domain-trained language models with embedded life accounting logic and regulatory compliance reasoning, the approach produces audit-ready documentation that assists the asset owners in meeting regulatory standards from aviation authorities such as EASA and FAA. Enhancing traceability to LLPs enables their safe re-entry into operational service, supports the module swaps market, and optimizes part pooling strategies. The result is a digital enabler for circularity in the engine lifecycle—preserving material value and maintaining uncompromised safety and compliance in aviation.
Bhate, Ujwal, Jain, Dilip Kumar, Kulkarni, Ninad, Kalaiyarasan, Aravindh, Jha, Ashish, Shenoy, Karthik
Overcoming the Carbon Neutrality Bottleneck: Multidimensional Innovations and Future Prospects of Carbon Capture, Utilization, and Storage (CCUS) Technology2026-99-17365/22/2026
As the global pursuit of carbon neutrality accelerates, carbon capture, utilization, and storage (CCUS) technology is emerging as a critical strategic pillar for achieving significant emission reductions and facilitating the transition to green development. This review systematically summarizes the principal technological pathways and recent advances in carbon capture, resource utilization, and storage within CCUS systems, with particular attention to innovative directions including advanced adsorption and separation materials, synergistic catalytic conversion, biological carbon sequestration, and mineralization-based storage. By examining representative engineering practices and industrialization cases both domestically and internationally, this paper summarizes the major challenges currently facing CCUS, including material costs, energy consumption, environmental risks, and large-scale deployment. The positive impacts of interdisciplinary integration, process system optimization, and policy coordination on the commercialization of CCUS are also discussed. The review indicates that overcoming bottlenecks in core materials and process technologies, improving regulatory frameworks and market mechanisms, and establishing clustered industrial ecosystems are essential for CCUS to spearhead the forthcoming low-carbon energy and green industrial revolutions. This paper envisions future development trends for CCUS technology, highlights its multidimensional strategic value for global carbon governance, energy security, and the circular economy, and offers theoretical references and cutting-edge insights for scientific research, policy formulation, and industrial decision-making in related fields.
Wang, Yingfei
Design and Implementation of an Intelligent Mobile Waste Classification and Collection Robot System2026-99-07025/15/2026
To address the growing demand for waste management, improve the efficiency and accuracy of waste classification, reduce costs, promote environmental protection and circular economy development, and solve environmental pollution and resource waste problems through technological innovation. This paper proposes an intelligent mobile waste classification and collection robot system. The system consists of a picking mechanical arm subsystem, a waste classification and collection subsystem, a self-moving chassis subsystem, and a solar tracking power generation subsystem. The picking mechanical arm subsystem actively collects waste through a mechanical arm combined with machine vision technology and deposits it into the waste classification device, while the waste classification and collection subsystem completes functions such as classification, compression, collection, and dumping, utilizing a navigation and positioning-driven chassis to achieve autonomous waste collection, simultaneously employing an AI (Artificial Intelligence) interactive voice broadcast device for waste classification promotion. The operation and control of each subsystem are fed back to the client through remote network connection devices, achieving “unified network management.”
Xia, Ying, Zhu, Huabing, Jia, Ruitong, He, Yifan, Hou, Wentao, Fu, Shaozao, Lin, Jiaoyang
Enabling Sustainable E-Mobility: An Edge–Cloud Collaborative Framework for Battery Lifecycle Health Management in Electric Vehicles2026-01-04604/7/2026
The rapid adoption of electric vehicles (EVs) is a cornerstone of the transition to sustainable transportation. However, uncertainty regarding battery degradation remains a significant obstacle, hindering vehicle energy efficiency, operational safety, and the recovery of end-of-life value. Accurate estimation of the battery state of health (SOH) and prediction of the remaining useful life (RUL) are therefore critical for sustainable vehicle lifecycle management. This study proposes an edge–cloud collaborative intelligent framework for in-vehicle deployment that leverages a Transformer-based architecture to jointly model SOH and RUL. The cloud-side model retains the full configuration to capture long-term degradation trajectories for high-accuracy RUL prediction. A lightweight edge-side model, engineered via pruning and knowledge distillation, delivers millisecond-level inference for real-time SOH estimation onboard the vehicle. To ensure efficiency, only four core health indicators are extracted for end-to-end prediction. Experimental validation across 77 battery cells demonstrates that the framework achieves SOH estimation with a root mean square error (RMSE) of 1.41% and RUL prediction with an RMSE of 2.59% (78 cycles). Furthermore, a periodic cloud-side update and over-the-air deployment mechanism ensure long-term adaptability and cross-platform scalability without full local retraining. This intelligent prognostic framework directly enhances EV reliability and sustainability by providing health-informed decision support for optimal vehicle operation, maintenance scheduling, and the reuse of second-life batteries. Consequently, it serves as a vital tool for advancing resource optimization and circular economy principles within the E-mobility ecosystem.
Gao, Weimin, Lv, Zhilong, Ou, Shiqi(Shawn)
Deep Learning-Based Screening of Retired Lithium-ion Batteries for Sustainable Lifecycle Management2026-01-70072/27/2026
Ensuring safety and consistent quality in lithium-ion battery manufacturing is essential for the reliable operation of electric vehicles and energy storage systems. Strict quality control measures during production not only enhance product safety but also reduce the number of defective units entering post-market recycling streams. However, variations in battery quality remain inevitable, making efficient downstream sorting an important complement to upstream manufacturing control. Efficient sorting of retired lithium-ion batteries is critical for battery second-life utilization and circular economy development. Based on 750 commercially recycled retired batteries, this study proposes a 1D CNN-Transformer hybrid deep learning framework for automatic screening of retired batteries. The framework first employs a 1D convolutional neural network to extract local features from time–voltage sequences and compress sequence length, followed by a Transformer encoder to capture global discriminative features during the charging process. Subsequently, a two-layer multilayer perceptron classifier produces the category predictions. Experimental results show that the proposed method achieves a classification accuracy of 95.33%, significantly outperforming conventional approaches. Further analysis reveals that the 1D CNN module improves accuracy by approximately 4% by providing efficient feature inputs for global modeling; charging data, compared to discharging data, offer richer information, boosting accuracy by 16.67%; incorporating temporal information under non-uniform sampling enhances time-series modeling effectiveness, yielding a 2.67% accuracy gain; and using only the first 4–12 minutes of charging data can still achieve 92.67% accuracy, indicating that the early charging phase carries high discriminative value. This study provides an effective technical solution for sorting retired batteries and offers valuable insights for advancing the battery recycling industry.
Xiao, Hualong, Luo, Gang, Wang, Li, Lin, Mingqiang, Wu, Ji
Life Cycle Assessment for Sustainable EV Battery Recycling: A Technical Framework for EBRR2026-28-00922/12/2026
Electric vehicle (EV) battery life cycle assessment (LCA) is emerging as a strategic necessity amid booming demand and tightening environmental regulations. This report consolidates key findings and recommendations for EBRR (Electric Battery Reuse & Recycling) to implement a comprehensive LCA program covering EV lithium-ion batteries from cradle-to-grave and cradle-to-cradle perspectives. The study confirms that global Li-ion battery demand is skyrocketing – projected to increase 14-fold by 2030[1] – amplifying the urgency for sustainable battery management (see Figure 1). It outlines the full life cycle stages of EV batteries (raw material extraction, manufacturing, use, and end-of-life) and compares linear vs. circular approaches. Using the ISO 14040/44 framework[18, 19] and industry-standard LCA tools, the report evaluates environmental impacts and identifies hotspots. Key findings show that mining and manufacturing dominate the battery’s carbon footprint, but end-of-life strategies can reduce lifecycle emissions by 30–40% through hydrometallurgical recycling, renewable energy integration, and second-life battery reuse. The implementation plan details a phased approach: team setup and training, inventory data collection (3–6 months), impact assessment, interpretation, and integration into EBRR’s corporate strategy. Technical challenges – data uncertainty, regional energy variability, scaling new recycling tech, and regulatory compliance – are addressed with mitigation tactics like sensitivity analysis and scenario modeling. Finally, the roadmap recommends actionable steps: transitioning from pyrometallurgy to cleaner hydrometallurgy (cutting recycling greenhouse gas (GHG) emissions nearly in half [3]), powering battery manufacturing with renewables (potentially halving production emissions[4]), designing for disassembly and second-life reuse (extending battery life and reducing need for new materials[5, 6]), and proactive policy engagement. Implementing this LCA-driven strategy will position EBRR as a frontrunner in responsible battery stewardship, achieving verified reductions in environmental impact (~30–40% GHG reduction) while meeting or exceeding emerging global regulations such as the EU Battery Regulation 2023/1542[53]and various Extended Producer Responsibility laws. This not only mitigates environmental and social risks but also enhances long-term profitability and resilience for EBRR in the fast-evolving EV industry.
Asokan, Gayathri, Raju cEng, Rajkumar, Dhananjaya, Chandan, Sattigeri cEng, Sudhir V
Comparative Assessment of Lithium-Ion Battery Recycling Strategies: Unveiling Challenges, Optimizing Benefits, and Exploring Future Potential2026-26-02011/16/2026
This research paper offers a comprehensive evaluation of lithium-ion battery recycling methods, tracing the entire journey from global demand to the practical challenges and solutions for sustainable battery recycling. It starts with the analysis of worldwide LIB demand growth alongside the exponential growth in volumes of spent batteries and recycling rates. The study focuses on the imbalance in production and recovery of critical battery components and its environmental and economic effects. The paper then systematically examines six major recycling methodologies: mechanical, pyrometallurgical, hydrometallurgical, biotechnological, direct, and ion-exchange recycling. It goes into detail about their advantages, limitations, and roles in maximizing the recovery of valuable metals such as lithium, cobalt, and nickel. Traditional techniques like hydrometallurgical and pyrometallurgical methods, and emerging approaches including bioleaching and ion-exchange, are evaluated for their technical effectiveness and sustainability. Utilizing a multi-criteria decision analysis framework, the study compares these recycling methods across technical, environmental, and economic factors. The role of cutting-edge technologies, including automation and artificial intelligence, is also explored and discussed for their potential to optimize recycling processes, reduce chemical waste, and scale operations to meet escalating global demand. Pushing the transition toward circular economy models and closed-loop systems, this paper underscores the importance of emerging recycling solutions to preserve finite resources and build a resilient and sustainable LIB supply chain. The strategic recommendations are provided with the aim to guide industries and policymakers toward efficient, scalable, and environmentally responsible battery recycling technologies, which are critical for supporting the clean energy transition and future technological growth.
Jain, Gaurav, Premal, P, Pathak, Rahul, Gore, Pandurang
Circularity and LCA: Enhancing Sustainability in the Indian Electric Vehicle Sector2026-26-02391/16/2026
The global shift to electric vehicles (EVs) is vital for reducing greenhouse gas emissions, but their sustainability hinges on effective battery lifecycle management. This review examines the interplay between Life Cycle Assessment (LCA) and circular economy (CE) principles in EVs, with a focus on both international trends and India-specific challenges. We analyze CE strategies such as extending battery lifespan, second-life applications, and recycling integrated with LCA to evaluate environmental impacts from raw material extraction to disposal. Key areas include battery chemistry, LCA methodologies, policy frameworks, and industrial practices, informed by a synthesis of over 50 peer-reviewed articles, technical papers, and sustainability reports. Challenges include inconsistent LCA baselines, low material recovery in informal recycling, and regulatory gaps, particularly in India. Despite these, innovations like solid-state batteries and advanced recycling techniques offer promise, potentially reducing emissions by 30–40 percent through closed-loop systems. Research gaps remain in areas like the durability of recycled materials, economic viability of CE strategies, and socio-ethical considerations. This review provides a holistic overview, actionable insights, and a roadmap for integrating CE into EV design and policy, especially tailored to India’s evolving automotive ecosystem. By addressing these issues, it aims to guide policymakers, industry stakeholders, and researchers toward a more sustainable, circular future for transportation.
Haregaonkar, Rushikesh Sambhaji, Kumar, Om, Sankar M, Gopi, Kumar, Rajiv
Reverse Engineering and Digital Twins in Powertrain Design: Enhancing Performance and Sustainability2026-26-00651/16/2026
This study explores the application of reverse engineering (RE) and digital twin (DT) technology in the design and optimization of advanced powertrain systems. Traditional approaches to powertrain development often rely on legacy designs with limited adaptability to modern efficiency and emission standards. In this work, we present a methodology combining 3D scanning, computational modeling, and machine learning to reconstruct, analyze, and enhance internal combustion engines (ICEs) and electric vehicle (EV) drivetrains. By digitizing physical components through RE, we generate high-fidelity DT models that enable virtual testing, performance prediction, and iterative improvement without costly physical prototyping. Key innovations include a novel mesh refinement technique for scanned geometries and a hybrid simulation framework integrating finite element analysis (FEA) and multi-body dynamics (MBD). Our case study demonstrates a 12% increase in thermal efficiency for a retrofitted ICE and a 15% weight reduction in an EV motor housing through topology optimization. The proposed approach not only accelerates R&D cycles but also supports circular economy principles by facilitating the remanufacturing of legacy components. This work contributes to the ongoing shift toward sustainable mobility by bridging the gap between legacy engineering and next-generation powertrain innovation.
Bernikov, Mark Alexandrovich, Kurmaev, Rinat
Advancing Circular Economy in India's Automotive Sector: Challenges and Sustainable Solutions2026-26-02381/16/2026
The purpose of this research is to examine the fundamental principles of a circular economy (CE) in relation to the automotive industry in India, which plays a vital role in the country's economy. As a result, energy consumption and environmental impacts also pose significant challenges. CE provide a transformative approach through the life cycle of a vehicle, guiding the automotive industry toward a more sustainable transportation system. In order to decarbonize this industry, the global automotive commission recommends that recycled plastic content in vehicles be increased to 20-25% by 2030. This target necessitates the recovery of plastics from end-of-life vehicles, though these materials are rarely integrated into compounds today. The automotive industry's reliance on plastics has grown substantially due to their lightweight properties, which enhance fuel efficiency, reduce CO₂ emissions, and improve versatility and mechanical performance. polypropylene polymer and several other polyolefins are used for components like bumpers. The most prevalent recycling method for polypropylene bumpers is mechanical recycling, yet it presents notable challenges. It is important to note that paint, in particular, affects both the aesthetic quality and the structural integrity of recycled materials. This review work also explores the primary recycling methods documented in literature, particularly those that have minimal environmental impact. Further, the study provides a comprehensive analysis of India's transition toward sustainability in the automotive sector, including procedures for waste disposal and reuse. The report emphasizes the industry's growing pressure to adopt circular and sustainable approaches in production, vehicle design, and waste management while emphasizing the principles of reducing, reusing, and recycling plastic waste.
Kumar, Vijay Bhooshan
Value-Engineered Design Optimization of a Recycled Plastic Bracket to Meet Natural Frequency Targets in Passenger Vehicles2026-26-03551/16/2026
Engine mount brackets are a primary structural components of passenger vehicles that supports the powertrain to the chassis via engine mounts. These brackets are important to control vibrations and the transmission of noise into the cabin as well as vehicle stability. Since they support the engine mounts, these brackets play a role in determining ride comfort and load distribution on the mounts and the engine. While traditionally made from steel, cast iron and aluminum, we are trying to redesign engine mount brackets with recyclable engineering plastics to fit current demands of light-weighting, cost efficiency, and sustainability. The present work is concerned with the design of a plastic engine mount bracket, which aims to hit specified natural frequency targets in order to avoid resonance and fulfill strict NVH (Noise, Vibration, and Harshness) requirements. Because of the superior mechanical strength, thermal stability, and vibration-dampening properties, PPS, glass-fiber reinforced polyamide (PA66-GF50), PEEK (polyether ether ketone), and other high-performance reinforced plastics like polyphenylene sulfide were taken into consideration. These materials can be used in structural automotive applications in place of metals. Through the Finite Element Analysis, modal analysis, CAE based durability simulations and vehicle-level testing the optimized bracket proven to meet structural and dynamic performance specifications. The findings confirm that, in the form of plastic bracket, recyclable designs can be technically feasible and sustainable alternatives to metal designs, which help reduce vehicle weight, increase fuel efficiency and vehicle manufacturability without sacrificing durability and safety.
Hazra, Sandip, Gupta, Deepak, Khan, Arkadip, Gite, Yogesh
High Efficiency Li-Ion Battery Recycling for Electronics2025-36-016712/18/2025
Lithium-ion batteries (LIBs) have consolidated their place in the technology market for the energetic transition, with global manufacturing capacity exceeding 1 TWh in recent years and costs falling in this competitive environment. At the same time, the number of end-of-life LIBs is increasing, stimulating the recycling industry to process battery streams, thus promoting the circular economy to meet the increased demand for strategic raw materials and decarbonization. Vehicle electrification is the main driver of battery production, but their end-of-life will take some time to be significant in volume in the next years. Consumer electronics such as smartphones, laptops and power tools are now available at an appropriate volume enabling the preparation of recycling industry for the moment. In this scenario, recyclers are looking for sustainable routes to absorb all these streams and the different LIBs chemistries (LFP, NCA, NMC, LCO, LMO) to recover the critical metals (Ni, Co, Cu, Mn and Li). Faced with these problems, Tupy in an Embrapii project with Tecnogreen LAREX at USP has developed a recycling route for EV batteries that extends its feed to electronic batteries in a flexible hydrometallurgical process. This work presents the results of this process, which includes the semi-pilot scale of 20kg LIBs obtained from electronics. Critical metals recovery efficiency was 71% of cell weight, leading for 83% of Co, 93% of Cu, 86% of Ni and 89% of Li. Such initial results exceed the Cu, Ni and Li efficiencies required by the European Union at the end of 2027.
Gobo, Luciana Assis, Ferrarese, Andre, Oliveira, Rafael Piumatti de, Martins, Thamiris Auxiliadora Gonçalves, Guillen, Daniela Romero, Silva Vasconcelos, David da, Tenório, Jorge Alberto Soares
Safety Model for Battery Resistance Monitoring and Lifecycle Optimization2025-01-051511/25/2025
This work proposes a novel framework for evaluating the second- and third-life viability of lithium-ion battery packs through the development of the RISE Index—a comprehensive metric based on Resistance growth, Integrity, Safety, and End-of-life usability. While previous research focuses on singular indicators such as residual capacity or State of Health (SoH), these approaches lack a unified, safety-informed structure for reuse qualification. This paper distinguishes itself by integrating multiple aging indicators, including resistance evolution, degradation theory, and thermal safety considerations, into a consolidated decision-making tool designed for practical deployment. The novelty lies in the formulation of the RISE Index, which fuses empirical data with electrochemical degradation mechanisms such as SEI formation, lithium plating, calendar aging, and cycling-induced impedance growth. The methodology includes a comparative analysis of Nickel Manganese Cobalt (NMC) and Lithium Iron Phosphate (LFP) chemistries using Electrochemical Impedance Spectroscopy (EIS), Direct Current Internal Resistance (DCIR), and model-based estimation to characterize resistance trends under varied operational conditions. Theoretical models for impedance growth link internal changes to observable resistance behavior. Findings indicate that LFP cells offer superior thermal and impedance stability, while NMC requires stricter monitoring due to accelerated resistance growth. The RISE Index enables stakeholders to classify and prioritize used battery packs for safe and efficient second- and third-life use, thereby addressing a critical industry gap. This integrated approach represents a significant advancement over prior work by embedding safety, usability, and degradation science into a unified lifecycle optimization framework.
Prakashkumar, Balagopal
Self-Healing Biodegradable Composites for Off-Highway Vehicles in Extreme Environments2025-28-021111/6/2025
Off-highway vehicles (OHVs) frequently operate in extreme environments—ranging from arid deserts and frozen tundras to dense forests and abrasive mining zones—where structural wear, impact damage, and environmental stress compromise their material integrity. Frequent repairs and component replacements increase operational costs, downtime, and environmental waste, making durability and sustainability key concerns for next-generation vehicle systems. This paper explores a novel class of self-healing biodegradable composites, inspired by biological systems, to address these challenges. The proposed materials combine bio-based resins, microencapsulated healing agents, and shape-memory polymers (SMPs) to autonomously repair microcracks and surface-level damage when triggered by thermal, UV, or mechanical stimuli. The design draws inspiration from natural self-healing systems such as tree bark and reptile skin, replicating their regenerative behavior to enhance structural resilience in OHVs. The composite’s biodegradability ensures environmental friendliness at end-of-life, aligning with circular economy goals. Laboratory-scale experiments and computational simulations assess tensile strength, fracture toughness, healing efficiency, and environmental stability (e.g., temperature cycling, UV exposure, and abrasion).
Vashisht, Shruti
Development of High-Efficiency, Fully Recyclable eMotors for Light Mobility Applications Produced in the EU2025-32-009811/3/2025
This article presents a new generation of electric motors developed for light mobility and industrial applications. The motor range is based on synchronous reluctance technology using non-rare-earth permanent magnets. Three continuous power levels have been developed: 2, 4 and 6 kW. The challenges related to that motor range is their high continuous performances (cooled by natural convection) under nominal 48V, and reparability easiness without adding complexity. These motors stand out thanks to their competitive manufacturing cost and peak efficiency above 94%, which is a remarkable performance for this power and torque class. A prototype of a 6 kW continuous power has been produced and benchmarked. The experimental test showed a high level of correlation with the simulation calculation.
CISSE, Koua Malick, Milosavljevic, Misa, Mallard, Vincent, Valin, Thomas, De Paola, Gaetano
The factory's hidden power grid25AUTP10_0310/1/2025
Why smart electrical distribution is the new frontier in sustainable manufacturing. From transitioning to renewable energy, embracing the circular economy and pursuing carbon offsets, today's automakers are actively working to become more sustainable. Many OEMs have big goals to become fully carbon-neutral by 2050. Some believe they can get there even earlier. But look past the cars and sources of energy right into the factories in which the vehicles of today and tomorrow are born and focus on a key question: how can carmakers make significant strides inside their plants to cut waste and improve sustainability?
Hamadani, Mariam
Sustainable Circular Future Mobility: Environmental Impact of Next-gen VehiclesEPR20250159/22/2025
The next generation of mobility, driven by shared, driverless, connected, and electrified vehicles, holds strong potential to advance sustainability through lower emissions and improved resource efficiency. However, critical questions remain regarding their true environmental impact, including battery lifecycle management, material consumption, and circular manufacturing practices. Sustainable Circular Future Mobility: Environmental Impact of Next-gen Vehicles explores these unresolved issues, focusing on the shift from internal combustion to electric vehicles, supply chain challenges, regulatory gaps, and the operational realities of sustainable productization. It also critically examines the risks of greenwashing, the need for consistent standards, and the role of intersectoral collaboration—with energy, urban planning, information and communications technologies, and waste management sectors—in building resilient, scalable solutions. The report provides strategic recommendations and actionable solutions to help stakeholders better navigate the transition toward a circular future for mobility. It further highlights the overlooked complexities in the Global South, emphasizing the importance of ethical market expansion and localized mobility strategies. Click here to access the full SAE EDGETM Research Report portfolio.
Abdul Hamid, Umar Zakir
Sustainable Design of Automotive Batteries2025-01-00015/8/2025
A consequence of the automotive industry's shift to electrification is that a significantly higher percentage of a vehicle's lifecycle CO2 emissions occur during the production phase. As a result, vehicle manufacturers and suppliers must shift the focus of product development from the 'in-use phase only' to optimizing the complete product lifecycle. The proper design of a battery has the highest impact to all other phases following in the life cycle. It influences the selection of materials, the manufacturing, in-use and end of life, respectively the recycling and recycling yield for a circular economy. Using real-life examples, the paper will explain what the main parameters are necessary for designing a sustainable battery. What are the low hanging fruits to be considered? In addition, it will elaborate on the relation as well as the impacts to other KPIs like safety, costs and lifetime of the battery. Finally, it will round up in an outlook on how batteries will evolve in the future where eco-design is the main driving factor. The paper is structured as follows: • CO2 concentrations within current state-of-the-art traction batteries, where can we focus our efforts? • Legislation boundary conditions for sustainable traction batteries in automotive • Overview on hot spots and main impact areas on sustainability improvements in all phases of the lifecycle • Lifecycle CO2 (cradle-to-grave) impact minimization strategies during the product development phase • Usage phase comparison NMC vs. LFP • Best-practice toolkits and organizational approaches • Design-to-CO2 examples: Material variation, manufacturing process improvements • Economic considerations such as serviceability vs. effort • Design for recycling examples: Guidelines for easier disassembly, Higher recycled raw material yield.
Braun, Andreas, Rothbart, Martin
Advanced Manufacturing and Materials: Vol. 1EPRCOMPV0220244/30/2025
Lee-Jeffs, Ann, Safi, Joanna, Muelaner, Jody Emlyn, Barkan, Terrance
Letter from the Guest Editors13-05-03-001612/31/2024
Letter from the Guest Editors
Farahani, Saeed, Vargas-Silva, Gustavo, Kazan, Hakan, Moradi, Mahmoud, Medina, Carlos
Development of Lubricants Using Re-Refined Base Stocks—An Effort toward Circular Economy04-18-02-000812/6/2024
Re-refining of used lubricating oil is an economically attractive and effective recycling method that contributes significantly to resource conservation and environmental protection. The effective re-refining process of used lubricating oil undergoes thorough purification to remove contaminants and to produce high yield and good quality base oil suitable for reuse in lubricant formulation. Used lubricating oils have various hazardous materials, these can be processed with safe and efficient methods required to recover high-quality base oil products. Typically, used lubricating oil is a mixture of various types of additives, base oils, and viscometric grades as per the different types automotive and industrial applications. Re-refined base oils can be re-used to produce lubricants such as industrial and automotive lubricants like passenger car motor oils, transmission fluids, hydraulic oils, and gear oils. API classified base oils into two categories namely mineral base oils API Group I–III and synthetic base oils Group IV–V. Re-refined base oils meeting API Group I and II quality standards are mostly produced by re-refiners. In this article, the author has evaluated lubricating oils: gear oil meeting API GL4 specifications based on 25% re-refined base oil to assess the performance of these lubricants in comparison to conventional base oil-based lubricants. This study includes physicochemical tests, lab performance tests (rust, corrosion, shear stability, and oxidation), and tribological performance tests, i.e., weld load, wear scar diameter, and friction performance by MTM was also evaluated. Test results show similar performance in terms of low temperature, oxidation, and friction performance in 25% re-refined base oil-based lubricant with respect to conventional base oil-based products.
Maloth, Swamy, Joshi, Ratnadeep S., Mishra, Gopal Swaroop, Samant, Nagesh N., Bhadhavath, Sanker, Seth, Sarita, Bhardwaj, Anil, Paul, Subinoy, Arora, Ajay Kumar, Maheshwari, Mukul
Performance Evaluation & Development of Engine Oil with Re-Refined Base Oil for Automotive Applications2024-01-430211/5/2024
The focus on sustainability has encouraged innovation across industries with a growing emphasis on minimizing environmental impact. In the transportation sector, optimizing engine lubricants emerges as a crucial avenue for achieving sustainable performance as used engine oil is the primary lubricants waste stream. Re-Refined Base Oil (RRBO) presents a compelling solution, offering a sustainable alternative to virgin base oils. By reclaiming and reprocessing used oil, RRBO not only minimizes waste but also embodies the ideology of circularity, promoting resource efficiency and environmental conservation. This study presents the collaborative efforts between an Indian Automotive OEM and Lubricant Technology Partner towards the development of engine oil utilizing Re-Refined Base Oil (RRBO) for automotive applications. Specifically, two formulations were targeted: a 5W-30 A5/B5 oil for Bharat Stage IV passenger car usage and a 15W-40 CI4+ oil for Bharat Stage IV commercial vehicle application, both incorporating 10% RRBO. Extensive testing was conducted to assess the physicochemical properties of the base oil and the finished oils containing RRBO. Bench tests were employed to identify performance of key parameters, including oxidation resistance, deposit formation, and corrosion susceptibility. Engine test bed and vehicle field testing were performed to evaluate the real-world performance of finished oils with RRBO. The results demonstrate that 10% RRBO-based formulations exhibit performance levels comparable to those formulated with virgin base oil, affirming the viability and efficacy of RRBO as a sustainable alternative. In conclusion, this study highlights the integral role of RRBO in advancing circular economy principles within the automotive industry without sacrificing performance. By embracing resource efficiency and waste reduction, RRBO contributes to a more sustainable and resilient lubrication ecosystem, paving the way for a greener and more responsible future.
Tyagarajan, Sethuramalingam, Singh, Samsher, Bondre, Sushil, Thanapathy, Saravana Raja, Dalvi, Preshit
Packaging and Processing: Life Sciences Industry Strives to Become More SustainableTBMG-512948/1/2024
Sustainability remains a dominant trend in packaging and processing, continuing to attract the attention of the life sciences industry and inspire its new initiatives. Although pharmaceutical and medical device manufacturers must prioritize patient safety and product protection, concerns about climate change, greenhouse gas (GHG) emissions, plastic waste, and pressure to move toward a circular economy are prompting a greater focus on improving the sustainability of their products and packaging.
Green Mobility and the Environment: A Dialogue among ResearchersR-5746/4/2024
Engineer Felice Esposito Corcione was awarded the Special Jury Prize in the environmental non-fiction category of the 16th Pelasgo 968 Literary Competition in Grottammare "Although it’s a complex topic, the book reads smoothly, like a well-delivered university lecture. And this is precisely the strength of Corcione’s work: explaining without oversimplifying, while offering concrete ideas for rethinking how we move and live on the planet." Nicoletta Bosio, writer and proofreader Embark on a transformative journey with Professor Felice E. Corcione's groundbreaking book, where environmental consciousness meets cutting-edge technology in mobility. Delving deep into the intricate relationship between mobility and the environment, Corcione offers insightful analyses of pollutants and lays the groundwork for sustainable practices. At the heart of Corcione's narrative lies the transformative potential of hydrogen, drawing inspiration from celestial phenomena and scientific innovation. With a focus on hydrogen's energy density and versatile applications in fuel cells, Corcione presents innovative solutions for sustainable transportation without compromising performance. Join Corcione and colleagues as they discuss pressing environmental challenges and chart a course towards a greener future. This book is more than just a read—it's a call to action to embrace "green mobility" and contribute to a sustainable future. Join the expedition towards zero-emission transportation and environmental stewardship. “This work is designed to outline a proposal for the rebirth of the planet in the name of renewable energy and a circular economy model affecting every economic sector—from agriculture and manufacturing to transportation.” Prisco Piscitelli Epidemiologist, Vice-president of the Italian Society of Environmental Medicine
Corcione, Felice E.
SAE BRIEFS w/Roberto Baldwin & Marc LeDuc WCX special edition134423/20/2024
From software-defined vehicles to EV batteries and the circular economy, the automotive industry is in the midst of a profound shift. To understand and adapt effectively, a meeting of the minds is needed -- a place where engineers can discuss trending topics, solve problems, and build community. Enter North America's largest technical mobility event, the WCX World Congress Experience. It's the place for the brightest and best across all engineering disciplines, as well as the entire supply chain community, to come together to discuss how the mobility industry can move forward. For insight on this year's event, we sat down with Marc LeDuc, Content Development Manager, Engineering Events for SAE International, to discuss what attendees can expect from the more than 1,200 sessions spanning technology, consumer metrics, regulatory standards, sustainability, and much more. If you're ready to problem-solve with your peers, register now for WCX 2024 taking place April 16 - 18, 2024 in Detroit, Michigan. Hope to see you there!
Hineman, Marcie
“Impact of Design Principles on End-of-Life and Recycling”2024-26-01631/16/2024
Automotive industry is a major contributor to global carbon dioxide (CO2) emissions and waste generation. Not only do vehicles produce emissions during usage, but they also generate emissions during production phase and end of life disposal. There is an urgent need to address sustainability and circularity issues in this sector. This paper explores how circularity and CO2 reduction principles can be applied to design and production of automotive parts, with the aim of reducing the environmental impact of these components throughout their life cycle. Also, this paper highlights the impact of design principles on End-of-Life Management of vehicles. As Design decisions of Component impacts up to 80% of emissions [1], it is important to focus on this phase for major contribution in reduction of emissions. Various factors such as material selection, quantity and weight of materials used in parts, design for durability, aerodynamic characteristics, design strategies, design for recycling, and compatibility of assembly processes contribute to such emissions. Research examines the feasibility of using recycled or bio-based plastics, improving part durability, design for disassembly and end-of-life recycling, and minimizing CO2 emissions in the process. Research also highlights challenges for using such material and recommended solutions. Intended Research emphasizes on use of tools like LCA (Life Cycle Assessment) analysis, QDCFS decision matrix, FMEA to find the areas of improvement, to make Product more sustainable and hence improving its End-of-Life Management. Part of the research also highlights data showing the use of recycled content in material and subsequent emission and End of Life impact. Additionally, this thesis investigates different ways of circular Economy Concept and CO2 reduction strategies in automotive industry. The results of this study can provide valuable insights to automotive manufacturers and policymakers to create more sustainable and resilient transportation systems.
Ali, Rifat Fahmida, Harel, Samarth, Shaikh, Taha, Chakraborty, Pinka
An Experimental Approach Towards Sustainable Solution for Material Recycling of ELV Plastic Bumpers and EV Batteries2024-26-01641/16/2024
A general automotive car is majorly composed of high strength steel (6%), other steel (50%), Iron (15%), Plastics (7%), Aluminum (4%) and others (Rubber, Glass, Textile) about 18%. End-of-life vehicles (ELVs) are a significant source of waste and pollution in the automotive industry. Recycling ELVs, particularly their plastic components, Li-ion batteries, catalytic converters, and critical technology components such as alternators, semi-conductor chips, and high tensile strength steel can reduce their environmental impact and conserve valuable raw materials. The paper conducts a SWOT analysis and a life cycle assessment (LCA) to evaluate the long-term viability and potential of ELV recycling, environmental impact, and carbon footprint. This paper examines the current state and challenges of ELV recycling in India and proposes a sustainable recycling solution for waste bumpers that includes paint removal, modification, reprocessing & recovery of precious metals from xEV Li-ion batteries. i Plastic recycling – Mainly PP from bumpers and other components. ii Precious metals recovery – Lithium, Cobalt, Nickel, Mn etc. Based on pilot line experiment sustainable recycling solution was established and validated through lab testing to compare the changes in physical properties. The paper also discusses the progress and challenges of achieving Carbon neutrality and circular economy objectives in the automotive industry and provides insights on sustainable material developments like e.g., long cellulose fiber reinforced thermoplastic for bumpers, reusability of raw materials in automobile parts manufacturing without compromising on quality requirements & provides data for rational decision-making and policy-making for ELV recycling in India.
Baviskar, Ajay, Khera, Pankaj, Telgote, Ashish, Dhuria, Himanshu, Sharma, Amit
Austempered Ductile Iron, Green Design Alternative for Circular Economy2023-28-013411/10/2023
In the current scenario, manufacturing of heavier products generates colossal waste, generates more CO2 emission, and negatively affects the environment. Customers not only pay higher product costs but also higher operational costs. This in turn demands the need for more recycling. Advanced high strength materials are a key solution to applications demanding higher strength, stiffness, durability & wear requirement, whereas low density materials like aluminium and magnesium won’t be a sustainable choice. With more and more battery electric & fuel cell vehicles, “light weighting” is a key priority. Austempered Ductile Iron (ADI) has a great advantage of superior mechanical properties compared to conventional ductile iron, aluminium alloys and even some steel forgings. Typically, ADI is used for high wear applications, whereas this paper will demonstrate the potential of using ADI for Structural applications. To display ADI’s potential on “light weight design”, an example of ‘Front Spring Anchorage’ is selected as a proof-of-concept. Analysis is carried out using Finite Element Method (FEM) on a redesigned component to validate its impact. Up to 40% reduction in weight is achieved on the component which greatly benefits commercial vehicles in terms of energy efficiency & cost. Overall, the paper will also exhibit ADI material’s contribution to concept of “sustainable design”, “circular economy” for a greener future.
Nalawade, Dinkar, Arcot, Pramaan, Khajure, Rahul
EDITORIAL: Smart engineering for sustainability23TOFHP10_0410/1/2023
Sustainability extends beyond just decarbonization. A term popping up more and more in executive and engineering-focused presentations is “circular economy,” referring to a closed-loop production cycle that seeks to minimize resource inputs and reduce or eliminate waste and emissions. Case in point: Rob Zemenchik, CNH Industrial's Sr. Manager for Product Sustainability, said at the SAE COMVEC conference in September that the company specifically seeks projects that deliver on circularity in the product life-cycle. CNH Industrial's roadmap to hit its 2030 and 2050 climate targets includes more than 150 specific projects, ranging from powertrains to hydraulics, he said. One of the “early success stories” is its work with British company Bennaman on an on-farm liquid fugitive biomethane production process.
Gehm, Ryan
Second-Life of Electric Vehicle Batteries from a Circular Economy Perspective: A Review and Future Direction2023-24-01518/28/2023
The second-life use of batteries from electric vehicles (EV) represents an excellent and cost-effective option for energy storage applications, including the control of fluctuations in energy supply and demand or in combination with solar photovoltaic and wind turbine. Indeed, these batteries are normally replaced from EV use before the end of their service life, when they still have 70-80% of the original capacity. Depending on the cell chemistry and the specific design, such batteries can still be employed in less stressful applications than the automotive one, including commercial, residential, and industrial applications. With the aim to promote the transition to a circular closed-loop economy for spent traction batteries, this study consists in a systematic literature review of available options for reusing EV batteries as a storage system in a factory environment, highlighting benefits and critical aspects.
De Luca, Cristina, Silvestri, Luca, Forcina, Antonio, Silvestri, Cecilia, Bella, Gino
SAE TOMORROW TODAY: Supporting a Circular Economy for EV Batteries134067/25/2023
When it comes to sustainability, the term "circular economy" refers to a process in which products are used again and again, thus reducing finite raw material consumption and curbing CO2 emissions. In transportation, the need to achieve circularity for EV batteries is particularly acute. According to recent studies, the projected demand for lithium will increase sixfold by 2030. This surge requires new engineering practices that reuse and recycle EV battery materials all the way upstream--and that's where SAE comes in. In the latest episode of Sustainable Mobility Briefs, Frank Menchaca, President, Sustainable Mobility Solutions at SAE International, discusses the importance of a circular economy for EV batteries and how SAE is designing engineering practices that will support the transition from gasoline power to electricity.
Hineman, Marcie
EDITORIAL: Engineering the ‘sustainability thing’23AUTD05_085/1/2023
Sustainable and sustainability are words that are fast becoming industry vernacular. They're woven into executive speeches, press releases, marketing, and engineers' messaging. That's because a gospel of sustainable practices is spreading fast among the leading automotive OEMs and their supply base. And as such a paradigm-setting trend deserves, we're focusing on it in this month's Automotive Engineering. “Meeting the needs of the present without compromising the ability of future generations to meet their needs,” is one definition of the term. In my view, sustainability is analogous to efficiency - of the product, of manufacturing and of human resources - the equitable treatment of employees and the community. At its heart is a circular economy that's not just about EVs and climate change.
Brooke, Lindsay
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