Ground mobility – heavy and light duty vehicles, autonomous ground vehicles, automotive.
Reuse of end-of-life carbon fiber reinforced composites in modular structures for mobility
EDAG Engineering GmbH
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EDAG has developed a new modular composite structure that demonstrates how circular design can be implemented in real vehicle applications.
As part of the Horizon Europe project RECREATE, the team engineered standardised, modular CFRP modules connected through reversible adhesive joints using thermally expandable particles (TEPs) and INDAR® primer by Applus Rescoll. These joints enable clean, non‑destructive separation of bonded components, allowing quick repair, replacement, and end‑of‑life recovery without compromising structural integrity.
To showcase the technology, EDAG redesigned the frame of the CityBot, an autonomous service vehicle with high utilisation demands. The modular CFRP frame replaces a complex welded steel structure while meeting all stiffness, durability and operational requirements. Simulations and testing confirmed equivalent mechanical performance with a 52% weight reduction, significantly improving vehicle efficiency. Life‑cycle assessment indicates a 49% reduction in CO₂/km emissions.
The demonstrator proves that circular FRP structures can be serviceable, upgradeable, and economically viable for heavy‑duty and automotive mobility.
The approach lays the foundation for wider adoption of repairable and recyclable composite systems, supporting European circularity targets and enabling long‑life, high‑utilisation mobility platforms.
- Novel design methods for durable, dismantlable and reusable lightweight composite structures.
- Detachable adhesive principles utilising heat trigger to separate components.
- Set of methods, materials and joining methods to achieve design for circularity.
- Undiscovered technologies for circular composite use, e.g. reshaping, laser-shock dismantling or high voltage fragmentation.
- Establishing a service for circular design of products independent from their material composition or purpose.
Challenges
- Reuse and remanufacturing are not possible for current vehicle designs.
- Dismantling and recycling are hampered by adhesives.
Solution
- Durable lightweight design for high-utilized vehicles.
- Concept of remanufacturing utilizing detachable adhesives.
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