— By Elaine Burridge — 

Germany’s Kollekt research project has been launched to develop fully recyclable automotive lighting components, with Covestro (Leverkusen, Germany; www.covestro.com) participating as one of the consortium partners. 

Kollekt, which builds on the findings of the Nalyses research project (2022-2025), is expected to run from June 2026 to May 2029, with total funding of EUR 4.37 mn from the German Federal Ministry of Research, Technology and Space (BMFTR, Berlin; www.bmftr.bund.de). 

Covestro said it will contribute its expertise in high-performance polymers and sustainable materials – its Makrolon polycarbonate (PC), Bayblend (PC/ABS), and Apec (PC or PC copolymers) brands are used widely in automotive lighting.

The project is to investigate how future headlamps can be made repairable and partially reusable, as well as which production and logistics processes will be required. Michael Kleinkes, responsible for global lighting development at automotive supplier and Kollekt partner Forvia Hella (Lippstadt, Germany; www.hella.com) said headlamps are rarely used in genuinely circular systems today. “We are therefore researching how materials can remain in use for longer, be reused, and help significantly reduce resource consumption.”

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A major part of the research will involve developing a flexible AI-powered robotic disassembly cell, complemented by an optimised sorting system that is to remove contaminants and separate plastic fractions. The recovered materials are to be characterised and processed for mechanical and partial chemical recycling.

Covestro said the insights generated by Kollekt will contribute to meeting EU end-of-life vehicle (ELV) recycling targets through to 2032 and support automotive manufacturers in fulfilling expected recycled-content quotas. 

Other partners in Kollekt are automotive manufacturer BMW, Geba, Fraunhofer IEM, Fraunhofer Umsicht, Paderborn University, Hamm-Lippstadt University of Applied Sciences, Helmholtz-Zentrum Dresden Rossendorf, and SW Maschinenservice.