SciTransfer
ZEvRA · Project

Circular Design System for Zero-Emission Electric Vehicle Manufacturing and Recycling

transportTestedTRL 5

Imagine if cars were built like Lego sets, where every part could be easily swapped, reused, or melted down without losing quality. Instead of digging up new metals, this project creates a blueprint for making EVs that use recycled materials for almost everything. It's like a master guide for car makers to stop wasting resources and start a closed-loop system.

By the numbers
84%
Material categories covered by zero-emission solutions
59%
Target impact on European EVs by 2035
5
Number of OEMs committed to innovations
The business problem

What needed solving

EV production currently generates significant CO2 emissions due to a reliance on virgin materials and a lack of standardized recycling methods. This prevents the automotive industry from achieving true zero-carbon transport.

The solution

What was built

A Design for Circularity methodology, a modular Circular Car Concept based on the Škoda Enyaq, and digital tools for traceability and circularity assessment.

Audience

Who needs this

EV Manufacturers (OEMs)Tier 1 Automotive SuppliersBattery and Material RecyclersSustainable Logistics Providers
Business applications

Who can put this to work

Automotive Manufacturing
enterprise
Target: Electric Vehicle OEM

If you are a car manufacturer dealing with high carbon footprints in production — this project developed a Design for Circularity methodology that validates zero-emission solutions for over 84% of material categories. This allows you to reduce reliance on virgin materials and align with 2035 zero-emission goals.

Materials Processing
mid-size
Target: Specialized Metal and Polymer Recycler

If you are a recycler dealing with fragmented EV waste streams — this project developed digital tools for traceability and circular business models for end-of-life logistics. This improves the economic viability of recovering rare-earth elements and high-grade alloys.

Automotive Supply Chain
any
Target: Tier 1 Component Supplier

If you are a supplier dealing with strict EU environmental regulations — this project developed a modular Circular Car Concept based on the Škoda Enyaq. This provides a validated way to integrate circular components into a replicable vehicle.

Frequently asked

Quick answers

How does this affect the cost of producing EVs?

Based on available project data, the project focuses on advancing circular business models for end-of-life strategies and logistics to improve economic feasibility and sustainable value creation.

Can these solutions be scaled to mass production?

The project aims to impact at least 59% of all European EVs by 2035 through the commitment of five OEMs and Tier 1 suppliers in the consortium.

Who owns the IP and how is it licensed?

Based on available project data, specific licensing terms are not provided, but the project involves 31 partners including 18 industry players and 5 OEMs.

Does this help with EU regulatory compliance?

Yes, it aligns with the EU goal of achieving zero CO2e emissions in the EV value chain by 2035 under the European Green Deal.

When will these tools be available for industry use?

The project period runs from 2024-01-01 to 2026-12-31, suggesting deliverables will be finalized by the end of 2026.

Consortium

Who built it

The consortium is heavily industry-weighted with 18 industrial partners (58% ratio), including 5 OEMs and Tier 1 suppliers. With 31 partners across 13 countries, the group balances academic research (5 universities, 6 research centers) with commercial application, ensuring that the developed circularity tools are grounded in actual manufacturing constraints.

How to reach the team

Contact Fraunhofer Gesellschaft zur Förderung der Angewandten Forschung EV

Next steps

Talk to the team behind this work.

Contact us to explore how to integrate ZEvRA's circularity tools into your supply chain.

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