recycled materials Archives

Eco-friendly shoes for World Car-Free Day, inspired by the Volvo XC40 Recharge

Cars and shoes… in some ways, they can be considered have similar functions since both ‘transport’ people around, though in very different ways. Cars use energy from the combustion engine or electric motor to move but with shoes, you have to provide your own energy. So it’s not unusual that on World Car-Free Day (September 22), Volvo Cars Canada and Casca footwear will launch a limited-edition sneaker. Available in Canada for $198 (about RM645), the shoes have been inspired by the fully electric Volvo XC40 Recharge.

“At Volvo Cars, we are committed to setting the highest standards of sustainability in mobility and that goes beyond electrifying our fleet to transforming all aspects of our business. The shoe we have created with Casca in celebration of World Car-Free Day, is one way to recognize the many steps we are taking on our journey to climate neutrality,” said Matt Girgis, Managing Director of Volvo Car Canada Ltd.

For a carbon-neutral future
As would be expected, the shoe is all about sustainability in the long term, and both brands have a shared vision for a carbon-neutral future. On Volvo Cars’ part, there is a commitment to reducing lifecycle emissions per vehicle by 40% by 2025 and producing only fully electric vehicles by 2030. Casca’s adoption of water-based, low-energy UV treatment processes coupled with their 2-year product warranty are a testament to their ‘buy less, waste less’ philosophy.

“The Volvo XC40 Recharge was designed to reduce environmental impact, so it was the perfect inspiration for the shoe,” said Kevin Reid Lead Director and Co-Founder, Casca. “Through this collaboration, we’re also celebrating many design firsts – our first shared design, our fastest production to market, and new recycled materials we’ve never used before.”

Scandinavian influences
The goal was to create a shoe rooted in conscious design. Scandinavian influences of the XC40 Recharge were purposefully integrated for a collaborative new interpretation of Casca’s trademark clean lines. For instance, the ‘Thor’s hammer’ headlight influence can be seen in the linework and panelling, delivering a more performance-inspired aesthetic to Casca’s popular Avro silhouette.

The Swedish flag is represented on one shoe tag, while the classic Casca yellow can be seen on the other, honouring the collaboration between the two brands as well as minimalist, Scandinavian design.

Recycled materials
Of course, an important aspect of the shoe is how it is made and its environmentally-friendly credentials come from having 10% of each sole made from recycled car tyres, the first time this material has ever been used in a Casca shoe as part of an intentional repurposing and recycling of materials. Furthermore, 7 recycled plastic bottles are used to make the yarn for each breathable, flexible knit upper.

Those two features are a preview of some of the initiatives by both companies. By 2025, Volvo Cars aims to increase the share of recycled and bio-based materials in their vehicles by 25%. By 2022, all of Casca’s knit uppers will be made from recycled or renewable materials.

*By 2025, Volvo Cars aims to increase the share of recycled and bio-based materials in their vehicles by 25%.*

“We know that being advanced isn’t just about great design and technology; it means implementing ethical and sustainable practices,” said Braden Parker, CEO and Co-Founder, Casca. “This is just one of many similarities we see between our brand and Volvo Cars, we both want to create something with intention that lasts.”

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BMW i Vision Circular Concept demonstrates how the ‘circular economy’ can be used for automobiles

Scrapping cars at the end of their useful life has been a common practice for decades. The metal and plastic parts that can be extracted can be reused for other goods – but not necessarily cars again. BMW thinks that cars of the future should be made from nearly 100% recycled materials. This will support the idea of a ‘circular economy’, where materials are continually reused, rather than discarded at the end of a single product’s lifespan, as in the conventional linear economy.

To demonstrate how the circular economy can be applied by the auto industry, the carmaker built the i Vision Circular concept which is a compact EV that might be in use in 2040. Working with companies like BASF and the ALBA Group, materials like recycled plastics are identified as sustainable materials that go into the construction of the i Vision Circular concept.

The recycling approach applies to the all-solid-state battery pack which is also manufactured almost entirely using materials sourced from the recycling loop. It will achieve much higher energy density with significantly reduced use of the most valuable resources, especially rare earth materials.

BMW also used 3D printing for many interior components, which further helps reduce waste, the automaker noted. The process produces less scrap material, and whatever isn’t used can be fed back into the production cycle as raw material.

Circularity from design stage
“We gave thorough consideration to circularity from the outset during the design process for the BMW i Vision Circular. As a result, this Vision Vehicle is packed with innovative ideas for combining sustainability with a new, inspirational aesthetic – we call this approach ‘circular design’,” explained Adrian van Hooydonk, Head of BMW Group Design.

The number of parts on the bodywork has been reduced as much as possible. Instead of having a chrome surround with bars, for example, the iconic kidney grille has been newly interpreted as a digital surface. Even the brand logo on the front end is engraved and the vehicle badge is laser-etched to avoid using extra add-on parts.

The surfaces below the windscreen are made from secondary aluminium. An additional sensor cluster between the two kidney elements groups together technological features, enabling simple disassembly within a single removable element. The bumper area further down is manufactured from recycled plastic with a sophisticated marbled surface.

Minimum parts and ease of disassembly
Having a small number of different mono-material groups with connections that can easily be undone is crucial for good recycling. For this reason, there are no bonded connections or composite materials and, instead, intelligent types of connection, such as cords, press studs and quick-release fasteners are used. A special socket wrench can separate the component parts joined by the fastener with a single rotation.

The tyres in ‘Vivid Blue Rubber’ are made from certified, sustainably cultivated natural rubber and have a slightly transparent appearance. Extra coloured, recycled rubber particles are added to the tyre compound for strengthening, creating an intriguing terrazzo effect and purposefully highlighting the reuse of materials.

The wheel rims are designed and manufactured with minimal materials use. Rim centres with maximum permeability provide brake cooling, while the more enclosed surfaces to the outer reaches of the wheels ensure the greatest possible aerodynamic efficiency. The wheels are fixed in place with a quick-release fastener at the centre of each wheel.

Only visible when looking from above, a narrow fin is integrated centrally in the rear section of the glass roof. It contains the communications and antenna technology, and provides information on the status of the vehicle (open/closed, charge level of the battery, etc.). It also integrates the high-mounted centre brake light.

Luxurious ambience with recycled materials
Inside, the i Vision Circular is also true to employing materials and production processes that are indicative of a responsible approach to the environment and its resources. But that does not mean it cannot have a luxurious ambience. For this, the interior designers carried out purposeful selection of materials. This involves using not just the right basic materials in the form of mono-materials but also clever new joining techniques for them which avoid the use of glue in order to ensure optimum suitability for dismantling and sorting at a later stage.

In order to minimise the amount of waste and offcuts, all components and materials will be manufactured to fit exactly using processes such as 3D printing. Any surplus material will be systematically fed back into the materials cycle.

The instrument panel is turned into a next-generation ‘phygital’ (a newly coined term that refers to turning digitality into a haptic experience) user interface. Here, it takes the form of a hovering, V-shaped sculpture that projects out into the cabin. At its heart is a 3D-printed, crystal body with nerve-like structures running through it, great visual depth and an enthralling lighting effect. This is where the vehicle’s “thinking” is visualised, allowing the user to see its intelligence at work.

The information area you would normally expect to find in a central information display is located above the instrument panel, at the bottom of the windscreen. This display area takes the Head-Up Display to a whole new level. All relevant information is projected onto the bottom area of the windscreen across its entire width. Driving displays for the driver can be found here together with communications functions and entertainment features for the passengers.

3D-printed steering wheel
The steering wheel forms a link between past and future at the same time as reducing the quantity of material and components. The rim has been 3D-printed from bio-based material, with the wood powder variant shown here giving the steering wheel a natural and warm feel. The unconventional, central positioning of the vertical spoke in gold-bronze adds a modern twist.

The display and operating surface below the windows visible on the outside of the car can be found on the inside too, forming a connecting element between interior and exterior. Here again, it extends back into the rear of the car and around the Hofmeister kink. Featuring the same crystal appearance as the instrument panel and ambient lighting, this element in the sidewall adds to the intriguing and mystical aura produced in the cabin.

BMW makes it clear that the i Vision Circular concept is not the basis or any future model. It has a range of next-generation EVs under development, referred to as ‘Neue Klasse’ (German for ‘New Class’) which may adopt some of the ideas from the sustainability-focused concept car.

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How plastic bottles provide Audi with seat upholstery for the new A3

Use of recycled materials in car parts has gone on for a long time as carmakers have tried to contribute to sustainable manufacturing processes. However, cost has also to be considered and with new technologies, recycling processes have been cost-effective enough to use.

Many disused items are recycled – from old jeans to coffee beans to coffee bean skins – and PET (commonly abbreviated from Polyethylene tErephThalate) bottles are popular for such use. In fact, the fashion industry produces jewelry, clothes and bags from PET bottles.

Audi is also using recycled material for its new fourth generation A3 for the first time as it continues to follow the corporate strategy of sustainability. The A3’s seat upholstery is made from secondary raw materials are being and up to 89% of the textile used comes from recycled PET bottles.

From old to new
In Germany, there are machines which accept PET bottles from the public, for which they get 0.25 euro (around RM1.20) per bottle. The bottles are then compressed for truck transport in order to save space. Once they have arrived at the recycling plant, they are sorted by colour, size and quality. Foreign matter such as the caps are separated.

A mill then crushes the bottles into flakes, which are washed, dried and melted down. Nozzles shape continuous plastic strands out of the mass. Once they have dried, a machine chops them into small pieces. This results in granulate, otherwise known as recyclate, and this undergoes extrusion to create threads. Wound onto coils, these are used in the final stage to manufacture materials.

In Audi’s case, they are transformed into yarn for the seat fabrics. The company says that in terms of look and feel, the quality standards are the same as conventional textile upholstery.

More than 100 PET bottles in a single A3
Up to 45 PET bottles with a capacity of 1.5 litres are used per seating system. On top of this, an additional 62 PET bottles are recycled for the carpet in the new A3. Other components in the interior are also increasingly made of secondary raw materials, eg insulating materials and absorbers, the side panel trims of the luggage compartment, the loading floor and the mats.

At present, the seat upholstery is not yet made completely of recyclable material. “The lower layer of woven material, which is connected to the upper material with adhesive, is what poses the challenge. We are working on replacing this with recyclable polyester,” says Ute Gronheim, who is in charge of material development in the textiles division at Audi. “It is our goal to make the seat upholstery completely from unmixed material so that it can be recycled again. We are no longer very far away from this.”

2020 Audi A3 — *The latest 4th generation Audi A3*

In the long term, all seat upholstery across all model series will be made of recycled material. The goal is clear: the percentage of recycled material in the Audi fleet is to rise considerably in the coming years.

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