Circular economy approaches in automotive lighting – insights from the Nalyses project

The Nalyses research project, which will be completed in 2025, is being conducted by partners FORVIA HELLA, BMW, Fraunhofer IEM, Heinz Nixdorf Institute, Hamm-Lippstadt University of Applied Sciences, Geba, and the associated partner Miele. The aim of the project is to investigate the influencing factors for a circular economy in the field of automotive lighting using the example of a headlamp. A key aspect is the analysis of methods for recycling end of life headlamps to recover materials for the next generation of headlamps and to evaluate their reusability. The article presents investigations and methods for recovering materials from used headlamps. These methods are evaluated based on how effectively they can recover materials for the next generation of headlamps and to what extent these materials can be reused. The goal was to identify the best practices that are both ecologically and economically sustainable. To support the development of a headlamp, a digital twin was created, which enables a detailed life cycle analysis at any time. This digital twin ensures that the expected CO2 footprint of the product can be analysed over its product life cycle during development to ensure optimal use and recycling of materials. This ensures a precise assessment of the environmental impact of future products. The final demonstrator of the project, developed based on the findings of the two points mentioned above and OEM requirements, presents the third key point of the research project: the design of a new product to enable a circular economy in the field of automotive lighting. The headlamp is designed to use circular economy recyclates and to serve as a material source at the end of its life. This represents an important step for automotive lighting towards a circular economy, where products and materials are used and reused for as long as possible.