The Lifecycle of Vehicles: Comparing Internal Combustion Engines and Electric Vehicles

Dismantling, recycling, and reusing components and materials are the key processes when it comes to handling end-of-life vehicles. The traditional ICE vehicles typically follow these steps: 

• Dismantling: Key components such as the engine, transmission, and exhaust system are removed and often refurbished for reuse or sale. 
• Recycling: Metals - steel, aluminium, and others - are sent to recycling facilities for reuse in automotive manufacturing and other sectors. 
• Fluid Recovery: The fluids, including engine oil and coolant, are drained and recycled where possible. 
• Non-metallic Materials: Plastics, rubber, and glass are sent to special facilities for recycling. 
• Hazardous Materials Management: Batteries, air conditioning refrigerants, and other hazardous materials are carefully disposed of following strict environmental regulations. 

Electric vehicles (EVs): a new recycling paradigm 

Electric vehicles have altered the end-of-life process somewhat, with significant differences noted particularly in the area of battery recycling: 

• Dismantling: As with ICE vehicles, EVs are dismantled and stripped of valuable components such as electric motors and inverters for potential refurbishment. 
• Battery Recycling: The most critical distinction between ICE vehicles and EVs lies in battery recycling. The usual lithium-ion batteries in EVs demand specialised processes to recover valuable elements like lithium, cobalt, and nickel. 
• Recycling and Reuse: Metal components are separated and recycled as with ICE vehicles. Similarly, non-metallic materials like plastics and glass are processed and reused. 
• Fluid Recovery: Although EVs contain fewer fluids than ICE vehicles, these are drained and recycled where possible. 
• Hazardous Materials Management: Again, as with ICE vehicles, EV batteries and other hazardous materials are handled following environmental guidelines. 

Material choices: key to the future of vehicle design 

The recent approach by VW, focusing on efficient recycling of EV components, is an excellent example of forward-thinking design. The choice of material in vehicle design is not just about performance and safety but also impacts the vehicle's end-of-life fate. 

The Flowdrill solution is an innovative response to this challenge, using an all-aluminium frame for ease of recycling. Unlike manufacturers using steel bolts, which necessitate separation before recycling, Flowdrill’s approach simplifies the entire process, reducing environmental impact. 

Second-life of EV batteries: an untapped potential 

With EV batteries being a significant part of the vehicle's weight, the question of their afterlife is both a concern and an opportunity. The ever-evolving battery technologies like solid-state batteries are promising longer lifetimes and higher recyclability, opening up a new landscape in the recycling arena. 

The future: a circular economy approach 

In conclusion, recyclability is a crucial factor in vehicle design, shaping the choice of materials and manufacturing processes. As sustainable transport takes centre stage, these considerations will only gain importance. Future vehicle design could prioritise recyclability and the circular economy, transforming our vehicles from potential waste to valuable resources. This path is not without challenges, but the goal – a cleaner, more sustainable world – is undoubtedly worth the journey. 

If we’ve sparked any questions today, you can  contact the Flowdrill team directly - we’d love to hear from you.