JLR aims to reduce its environmental impact by incorporating recycled materials in seat foam for its upcoming electric vehicles.
The British automaker is collaborating with Dow and Adient to tackle the complex recycling of polyurethane seat foam — a material that typically ends up in landfills. Testing of these recycled components in pre-production vehicles is scheduled to begin later this year.
This initiative forms part of JLR’s broader vision for a “circular seat” design. The new approach could cut CO2 emissions from seat production by half compared to current manufacturing methods.
The company’s dedicated research facility focuses on material reuse challenges. Engineers have identified that component separation during vehicle dismantling poses a significant hurdle, particularly when dealing with mixed materials or complex assembly methods.
BMW unveiled its own circular economy concept in 2021, claiming complete recyclability and 100% recycled material usage. Ford pioneered similar sustainability efforts years earlier, incorporating recycled denim into vehicle sound insulation.
Beyond seating, JLR is developing simplified front-bumper foam compositions to enhance recyclability. The company has also partnered with suppliers to integrate aluminum stamping scraps back into new body panels.
These sustainability measures take on added significance for electric vehicles. While EVs eliminate tailpipe emissions, their manufacturing carbon footprint becomes a more crucial environmental factor.
JLR plans to transform Jaguar into an all-electric brand, beginning with a luxury GT model inspired by the Type 00 concept scheduled for late 2024. The company will also expand its electric offerings across the Land Rover range.
The push toward recyclable materials reflects a growing industry trend. Manufacturers are increasingly focusing on reducing waste and emissions throughout the entire vehicle lifecycle — from production to eventual disposal.
At the heart of this transition is the circular economy model, which emphasizes material reuse over the traditional “take-make-dispose” approach. JLR’s research suggests that reimagining component design could significantly reduce manufacturing emissions while creating more sustainable supply chains.
