A team of students from TU Eindhoven (TU/e) has developed an innovative sustainable car, “Phoenix”, which aims to revolutionize the way materials are used and recycled within the automotive industry. Leveraging mono-material structures, Phoenix allows for a high percentage of its components—up to 75%—to be reused in new vehicles, setting a new standard in circular material usage and sustainability.

Material Circularity and Closed-Loop Recycling
At present, automotive recycling rates are around 88% in the Netherlands, but much of the recycled material is downgraded, restricting its reuse in high-quality applications. Phoenix addresses this challenge by using materials that retain their integrity and quality, even after recycling, allowing them to be reused directly in similar applications. The design eliminates permanent bonding between materials, enabling easy disassembly and recycling. This process represents a shift toward closed-loop recycling, where materials maintain their original quality and can be continuously repurposed, reducing both waste and the need for virgin resources.

Extending Battery Lifespan
The team also tackled one of the significant challenges in sustainable design: battery longevity. Phoenix uses a modular battery system that allows individual modules to be added as needed. These batteries are only activated during long journeys, which minimizes wear and enhances their lifespan. By reducing charging cycles, the Phoenix battery setup achieves up to 60% longer life, contributing to the vehicle’s sustainability.

Meeting Regulatory Goals
The Phoenix project also aligns with upcoming EU regulations that aim to increase circularity in automotive design and production. These regulations will require that vehicles must consist of a set percentage of 25 percent recycled plastic, of which 25 percent must be closed-loop recycled from cars. Phoenix’s mono-material approach could help the automotive industry meet or even exceed these targets, supporting broader sustainability and circular economy goals across Europe.

Pioneering a Sustainable Future
The Phoenix car from TU/e serves as an example of what’s possible when designers and engineers prioritize material innovation and circularity. This project highlights the potential of mono-material solutions to change the automotive industry, creating a future where vehicles not only minimise environmental impact but also contribute to resource conservation.

Source: TU/e
Photo: TU/e