Car parts like the bumper do not have to end up in a landfill, even if they are damaged. The bumper of the 2023 IVET show car highlights the potential of recycling: At the end of a car’s lifespan, this part is dismounted, crushed, and turned into a granulate, ready to create a new bumper. This closed-loop system can eliminate waste and the need for new material.

The 2023 IVET show car’s door panels feature inserts and upper sections made from ABS, which comes from offcuts and remnants of the plastic production process. The core structure of the door is formed from polypropylene derived from recycled plastic. This process involves breaking down plastic waste, cleaning it, and reforming it into usable granulate. These plastics, which would otherwise have been incinerated or sent to landfill, now constitute 30% of the door inserts.

While conventional dashboards often feature many components and materials, the dashboard of the 2023 IVET show car adopts a pared-down approach with just two layers. The underlying layer – the plastic carrier – is created from a blend of PC and ABS recyclate, sourced from non-conforming products and leftovers from the injection moulding process. The mono-material upper layer is crafted from recycled PET bottles; these are crushed and transformed into granules. Fibres are then extruded and made into fabric. The double-layered fabric consists solely of one material, ensuring a more straightforward recycling process at the end of the vehicle’s lifespan.

The wheel arches of the 2023 IVET show car incorporate materials such as recycled 12V car battery covers, former bumpers, and even plastic caps from PET bottles. Salvaging these materials from post-consumer waste exemplifies the closed-loop principle – transforming discarded items into modern car components.

The 2023 IVET show car’s hook lock system is manufactured using post-consumer recyclate, a material derived from parts that have reached the end of their operational lifespan. Specifically, old 12V car battery covers serve as the primary source material. These are processed, shredded and cleaned to produce new material. Consistent quality is ensured, as there is a continuous influx of car batteries, and their uniform composition eliminates the need to sort different battery types.

The boot carpet in the 2023 IVET show car is primarily sourced from used PET bottles, categorised as post-consumer recyclate. The PET bottles are processed to produce polyester fibres, which are subsequently used to create carpets for the boot.

A core constituent of the 2023 IVET show car’s tailgate cladding is polypropylene, derived from post-consumer recyclate. This involves repurposing plastic waste; after separating, shredding and cleaning, it is converted into granulate, which is then moulded into new automotive parts. This approach not only prevents waste from being incinerated or sent to landfill but also helps to conserve oil resources while reducing CO₂ emissions.

Conventional car headliners usually pair decorative fabric with polyurethane (PUR) foam, a combination that can complicate the recycling process. A fresh approach was taken for the 2023 IVET show car. The entire headliner consists of a mono-material – a 3D knitted fabric sourced from recycled PET bottles. This reduces the car’s carbon footprint and makes it easier to recycle in the future. The polyester spacer is not only fully recyclable and pleasant to the touch, but it also enhances the interior aesthetic and aids in soundproofing inside the vehicle.

Exemplifying the use of recycled materials, the 2023 IVET show car’s water canal cover is a feature already found in Škoda’s commercially available vehicles. Out of sight, this component is exposed to the elements and has different properties to interior parts, allowing it to pioneer the use of recycled material. Specifically, it is made of polypropylene (PP) derived from recycled 12V car battery covers, which undergo a process of shredding and cleaning before being remoulded into the car part.

Echoing the approach for the 2023 IVET show car’s body, interior parts, and upholstery, the toolbox or charging cable compartment under the boot floor is crafted from recycled materials. It is constructed from extruded polypropylene, originating from used plastic pallets. These are shredded, cleaned, and transformed into granulate, ensuring a steady and high-quality source of polypropylene. The process not only reduces the carbon footprint but also produces a compartment that is lightweight, robust, and easily recyclable.

Traditional foot mats comprise a mix of polyester (PES) and polyurethane (PUR), making the recycling process more challenging. However, the 2023 IVET show car introduces foot mats made entirely of polyester, including material from recycled PET bottles. This mono-material composition not only simplifies recycling at the end of the vehicle’s lifecycle but also allows the mats to be transformed into new foot mats or other auto components, such as wheel arches.

The floor covering of the 2023 IVET show car is made from repurposed polyurethane (PUR) mattresses, collected from households and hotels. Having been thoroughly steam-cleaned, these post-consumer mattresses are cut into small pieces called Greenflocks, which are then combined with a polyester (PES) binder and shaped under pressure into the final product. This method not only innovatively reuses consumer waste but also ensures that the floor covering can be fully reprocessed at the end of its lifecycle.

The sill covers of the 2023 IVET show car exemplify an eco-innovative approach of using recycled fryer oil instead of conventional oil to produce plastic granulate. The use of a biopolymer, derived from a commonly discarded kitchen product, contributes to reducing both the consumption of fossil fuels and the carbon footprint of the sill covers. The material made from fryer oil possesses the same qualities and performance as that produced from crude oil.

Taking a similar approach to the floor covering, the dashboard damping in the 2023 IVET show car also makes use of recycled polyurethane (PUR) mattresses, sourced from households and the hospitality sector. These old mattresses undergo a rigorous recycling process. First, they are steam-cleaned and then cut into small pieces known as Greenflocks. Mixed with a polyester (PES) binder, the material is then pressed into the desired shape. This application not only diverts consumer waste from landfills but also ensures the recyclability of the dashboard damping at the end of its lifecycle.

The dynamic seals in the 2023 IVET show car evidence an innovative leap in rubber recycling. Traditional challenges in using recycled rubber are overcome by devulcanization to restore the material’s plasticity. This innovative approach transforms previously unusable rubber waste into the dynamic seals showcased here.

In the 2023 IVET show car, sustainability takes the front seat. The headrests use recycled polyester (PES) fibres derived from PET bottles instead of traditional polyurethane (PUR) foam. These headrests are designed with a mono-material fabric for the exterior, composed of 100% recycled PET fibres, and the entire unit is fully recyclable. In line with the closed-loop principle, the headrests can be transformed into new polyester fibres and auto parts after their lifecycle. Fibres from certified sheep’s wool represent an alternative filling for the headrests. Also using mono-material technology for the outer fabric, these headrests support environmental stewardship, combining recycled materials with the sustainable use of natural resources.

In the highlighted rear-seat structure of the 2023 IVET show car, polyurethane (PUR) foam is cleverly repurposed. Recognised for being hard to recycle, the foam in this case is sourced either from old mattresses (post-consumer recyclate) or from production waste (post-industrial recyclate).

For the 2023 IVET show car, the innovative seat inserts are made using recycled extruded polypropylene (PP). This material is derived from old plastic pallets, giving new life to what would otherwise be waste. The concept replaces the traditionally used polyurethane (PUR) foam to enhance the part’s recyclability. An alternative approach involves using shredded polyurethane (PUR) from both discarded mattresses and production waste. This method repurposes materials that are typically challenging to recycle.

The 2023 IVET show car introduces a sustainable development in car design with its front seats. Featuring a new shell construction, the backrests are not only slimmed-down for more interior room but also lighter, reducing the car’s overall weight and carbon footprint.

The sample was developed in cooperation with Adient. Shell Foam is Adient‘s patented innovation product.

The steering wheel in the 2023 IVET show car boasts a cover crafted from non-animal-derived leatherette. This innovative cover is built on a base layer of 100% recycled polyamide (PA) fibre, which can be sourced from textile and industrial remnants as well as reclaimed fishing nets. A polyurethane (PUR) coating is applied over the recycled base, highlighting an intelligent approach to repurposing waste to make sustainable auto parts.