The automotive industry has always been at the forefront of technological innovations, but in recent years, there has been a growing interest in sustainable innovation. One of the challenges of the near future of automotive manufacturing is the use of recycled thermoplastic elastomers (rTPU) for the production of bumpers and automotive components. That plastics are irreplaceable in the automotive industry is evident. It has replaced metal in many applications, helping to reduce the weight of cars, CO2 production and fuel consumption. A somewhat more complicated process is the use of recycled materials inside the passenger compartment, due to stringent emission and odour requirements. To date, PET bottle recycling technologies have proven successful in the production of carpeting and flooring, while recycled fabrics are used for floor damping. Thermoplastic polyurethane (TPU) is a polymer of particular interest and whose use tends to grow over time, as it has special mechanical and physical properties that make it the most widely used material when high mechanical strength and elasticity in response are required. On the other hand, TPUs are among those classes of polymers where recycling is least developed. We will see in this article the main initiatives of car manufacturers and the prospects for the sector. Case studies: Toyota, Audi, Volkswagen Sustainable mono-material design in the context of life cycle assessment is becoming increasingly popular in the automotive industry, especially in the passenger compartment. Thermoplastic polyurethanes (TPE) are already present in car furniture: in the storage shelves; in 3D-printed seat backs; in the insulating rings that secure the front seats to the floor, which are very important for reducing vibrations; the headrests; in the glove box. Among car brands that have historically been committed to environmental protection, Toyota has always stood out for its long-term goals. Increasingly, the company believes in studying more eco-friendly designs by introducing raw materials with lower carbon emissions and fewer parts. Already since 2015, Toyota has a target to reuse and recover 95 per cent of the average weight per vehicle per year with a reuse and recycling rate of 85 per cent. From Toyota bumpers, plastic is obtained to make new car parts. In 2014, the National Scrap Program project started in the US with the aim of sourcing from all Toyota car manufacturers in North America, who could either bring in bumpers cracked during the transport of new cars to dealerships or send those from end-of-life cars for recycling. Audi is experimenting with different technologies: mechanical, chemical and also physical recycling. Audi is working to identify and use as many alternative types of materials as possible, while identifying the best processing and recycling techniques with the aim of creating closed loops. 'Our goal is to extract as much plastic as possible from the car at the end of its life cycle so it can be recycled,' explains Mike Herbig, who works in Audi's polymer team. Today, a car contains more than 200 kg of plastics and composites, e.g. bumpers, bonnets, various parts of the passenger compartment and the air conditioning system. The mixed plastic that is recovered is first mechanically crushed and separated from the other materials, then it can be processed into granules ready to be reused. The plastic must meet high quality requirements and the criteria do not change if the materials are recycled. The most important are resistance to impact, heat, weathering and fluids, including oils and solvents. Then there is dimensional stability and tactile, visual and olfactory sensation throughout the car's life cycle. All this without forgetting the environmental requirements. In the future, Audi intends to integrate various recycling technologies to recover as much plastic as possible from old vehicles and reuse it in new ones. In the Audi Q4 e-tron, for example, there are already 27 components made from recycled materials, including the door hinge covers, wheel arch frames and shells as well as aerodynamic spoilers at the wheels; all parts that have special mechanical properties. There is also a lot of recycled plastic inside the Audi Q4 e-tron, in this case used for insulation and damping materials, but also in many of the visible surfaces, such as the floor covering and luggage compartment. The S-line versions' sports seats are upholstered in leatherette combined with Dinamica microfibre, which has the look and feel of suede, but is made from 45 per cent polyester fibres derived from recycled PET bottles. Volkswagen has announced ambitious plans to become a manufacturer of completely carbon-neutral vehicles by 2050. The cars in Volkswagen's ID. Volkswagen's 100% electric range will adopt recycled materials for their interiors, already adopted on the ID. Buzz. In particular, the interior of the ID. Buzz is a combination of alternative materials made of plastic recovered from the oceans or from old PET bottles (63 500 ml bottles). It has seats upholstered with a material made of Seaqual® yarn, consisting of 10 per cent recovered marine microplastics and 90 per cent recycled PES yarn. This saves Volkswagen 32 per cent of CO2 emissions compared to using conventional materials. If we look further, we find that in the seat covers with ArtVelours Eco®, the share of recycled materials is 71%, while the headliner and floor are areas made entirely of recycled polyester. Recycled plastic is also found in the insulation layer of the floor and the same applies to components such as the underbody lining and wheel arches. Benefits of using rTPU for bumpers and automotive components Reduction of CO2 emissions: The adoption of rTPU enables a significant reduction in CO2 emissions during the production of automotive components compared to virgin materials.This is a crucial step for the industry in achieving its greenhouse gas emission reduction targets. Resource conservation: The use of recycled materials contributes to the conservation of natural resources by reducing the need to extract virgin raw materials such as oil. Waste reduction: By using rTPU, the automotive industry also contributes to the reduction of plastic waste and the problem of environmental pollution. Competitiveness: Automotive companies that adopt sustainable solutions are more competitive on the international market and attract customers who are sensitive to environmental issues. Gianeco, a reliable partner for recycled thermoplastic elastomers The use of rTPUs in bumpers and automotive components is one of the challenges for the future of the automotive industry. The use of recycled thermoplastic elastomers, like any recycled plastic material, also improves the image of the industry and meets the expectations of increasingly sustainability-oriented consumers. With the continuous development of technologies and processes, we can expect further improvements in the automotive industry in terms of sustainable innovation. If you are already using thermoplastic polyurethane polymers in your production and would like to test Gianeco's recycled material please contact us now.