BASF and its partners are set to present two technologies at K 2025 that allow for the recycling of polyamides from end-of-life vehicles. While metal recovery from decommissioned vehicles has been standard for decades, about 200 kilograms of plastic per vehicle are often incinerated. The new technologies aim to change this, especially with upcoming requirements from the End-of-Life Vehicle Regulation (ELVR). Pilot projects show how automotive waste can be used as material and returned to a closed cycle for the car industry.

BASF developed a chemical recycling process that recycles used and contaminated plastic parts – including used oil pans from ZF Group vehicles. The core of the process is depolymerisation, where the long polyamide chains break down into their original monomers. The caprolactam monomer obtained from PA6 is then purified. This removes impurities that would have remained with mechanical recycling and potentially reduced the material's quality and safety.

The material is then repolymerised into high-quality polyamide, which is processed into a compound suitable for demanding car industry components, closing the automotive-to-automotive loop.

"What used to be considered non-recyclable is now the starting point for high-quality new products," said Martin Scheuble, Team Leader Circularity Engineering Plastics at BASF.

ZF Group processed the recycled material into a chassis component for Mercedes-Benz. Tests show that depolymerisation allows for polyamide compounds that can be used without compromising performance or other chemical and physical properties.

"This project highlights the potential of recycled plastic - even for technically demanding applications - and underlines ZF's innovative strength in establishing sustainable material cycles," said Dr. Michael Lohrmann, Director Materials Technology at ZF.

Solvent-based recycling of shredder residue

A second pilot project focuses on recycling automotive shredder residue (ASR) – a mixture of materials left after the removal of mostly metals and glass. Close cooperation with a recycling company, using new sorting and processing technology, has allowed the polyamides to be extracted from this mixture in a largely pure form.

This polyamide fraction was the starting material for a solvent-based recycling process. In this process, the polymer chain is selectively dissolved with a solvent, purified and then reprocessed into PA6 compounds.

Poppelmann manufactured and tested a chain guide rail in series production at Mercedes-Benz using this technology.

"The project impressively demonstrates that solvent-based recycling is a practical alternative for plastics that are difficult to recycle mechanically. It makes an important contribution to the holistic circular economy - from the car back into the car," emphasised Steffen Meyer, Team Leader Production Technology at Poppelmann.

Life cycle analyses (LCA) confirm that both the solvent-based and depolymerisation technologies offer substantial CO2 emission savings compared to both conventional polyamide production and traditional plastic recycling methods like thermal recovery.

BASF offers a range of recycling solutions, stating that targets are achieved only if technologies are used in a complementary manner, depending on the type and availability of waste.

Jana Kragenbring-Noor, Head of Sustainability & Environmental Protection at Mercedes-Benz, explained, "Mercedes-Benz is committed to the use of secondary raw materials in its vehicles today and in the future as part of resource conservation and circularity. To continuously increase the availability of such sought-after secondary materials, the expansion of existing and new recycling technologies is essential."

"We are continuously improving the efficiency of physical methods such as mechanical and solvent-based recycling. In addition, we are convinced that complementary technologies such as chemical recycling, which includes depolymerization, pyrolysis and gasification, are necessary to further promote the circular economy and reduce the plastic waste that still ends up in landfills or is incinerated today, as well as the potential to obtain high-quality recycled plastics," explained, Dr. Martin Jung, President of BASF Performance Materials.

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Pre-owned car marketplace Cars24 has announced the launch of AI Labs, a dedicated initiative designed to develop artificial intelligence-native products and support early-stage entrepreneurs.

As part of the program, the company has committed a USD 20 million investment fund targeted at startups and development teams building transformative AI technologies.

The move marks an expansion of Cars24’s internal technology strategy, where machine learning and artificial intelligence models have already been integrated into core business operations to manage decision-making workflows and customer experience interfaces. Through AI Labs, the company will extend its technical resources externally to independent software engineers and startup founders.

To establish the infrastructure for the program, Cars24 has partnered with technology providers including OpenAI, Amazon Web Services (AWS) and ElevenLabs. This ecosystem will provide participating developers with cloud infrastructure, technical expertise, distribution networks and advanced language and voice synthesis models to accelerate product deployment.

The operational focus of AI Labs is divided into three primary activities:

• Build: Developing proprietary AI-native applications and contributing to global open-source software innovation.
• Partner: Collaborating with established artificial intelligence firms to encourage industry experimentation and technology adoption.
• Invest: Supplying seed capital and strategic support to early-stage businesses building software categories.

Beyond direct equity investments, the initiative will fund community engagement programs, including regional hackathons, builder incubation programs and collaborative open-source projects designed to stimulate developer experimentation.

Vikram Chopra, Founder and CEO, Cars24, said, “Every major technology shift creates a handful of companies that go on to define the future. We believe AI is the biggest shift of our generation, and the opportunity ahead is far larger than anything we've seen before. Over the last few years, we've seen AI fundamentally change how we operate, build products, and serve customers AI Labs is our way of giving back to the ecosystem that is shaping this future. We want to back founders early, help them move faster and support the people building things that seem impossible today but inevitable tomorrow.”

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Automotive supplier Valeo and Electronic Design Automation software provider Zuken have announced a strategic partnership to develop an open, artificial intelligence-assisted electronic design platform. The collaboration will operate under a joint program named the ‘Zuken Valeo InnoLab’.

The initiative integrates Zuken's AI architecture with Valeo’s custom AI agents and industrial data to create a real-time collaborative ecosystem between software tools and engineers. The primary objective of the program is to reduce hardware design timelines while maintaining structural robustness across complex automotive electronic systems.

The technical development framework spans the entire electronic design flow and is organised into four main operational areas:

• Functional Generative Design: Valeo will deploy its generative AI models within Zuken’s System Planner software to instantly generate and evaluate multi-criteria system architectures based on predefined corporate standards.
• Digital Continuity: Zuken’s open architecture will interface with Valeo’s existing digital ecosystem to provide end-to-end data traceability. This integration is designed to comply with the Automotive SPICE 4.0 (ASPICE4.0) Hardware Engineering process group standard, allowing Valeo's AI to process data and execute automated actions directly within the platform.
• Assisted Detailed Design: Valeo will integrate virtual AI copilot agents to assist engineering teams in real time with hardware rule verification, solution searching, and constraint implementations. Concurrently, Zuken is developing native AI functions to accelerate schematic entries by drawing from Valeo’s standardised components database.
• Automated Placement and Routing: Physical circuit integration will utilise Zuken’s Design Force engine, which features automated placement and routing algorithms. Valeo will use Zuken's software development kit to train the AI engine against specific automotive environmental and physical constraints to achieve correct initial executions.

Christophe Le Ligne, Vice-President – Research and Development, Valeo, said, “For Valeo, Zuken is much more than a software provider; it is a true innovation partner. The power of Zuken’s AI roadmap, combined with the exceptional openness of its architecture, allows us to hybridise our own artificial intelligence tools with their engine. This win-win partnership is the best way to tackle the challenge of automotive complexity by slashing our design times while guaranteeing 100% robustness.”

Ryosuke Takagi, Executive Officer and General Manager – R&D Division, Zuken, added, “Our vision at Zuken has always been to provide intelligent tools that adapt to our customers’ most complex challenges. Collaborating with a technological leader like Valeo pushes our ‘Autonomous Brain’ roadmap to its highest level of performance. By opening our System Planner, Design Gateway, and Design Force solutions to Valeo’s AI agents, we demonstrate that the true power of AI in engineering lies in the alliance between a high-performance software engine and expert industrial know-how.”

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Artificial intelligence software developer Helm.ai has launched two foundation models, GenSim-3 and VidGen-3, establishing a native Full HD (1920x1080) resolution standard for generative simulation across a 6-camera, 360-degree surround-view suite.

The architecture delivers 5x the pixel density of industry benchmarks to assist automotive developers facing the limitation where physical collection of edge cases becomes logistically restrictive.

Traditional generative world models typically cap resolution at roughly 0.4 megapixels per camera. Helm.ai’s platform outputs a native 2 megapixels per camera, yielding a synchronised 12-megapixel synthetic canvas per timestep. This specification matches the hardware parameters of production-grade vehicle cameras to reduce the domain gap for SAE Level 2 through Level 4 autonomous vehicle development.

The platform functions as a virtual sensor twin by mathematically replicating physical constraints and hardware anomalies, including lens flares, sensor banding patterns, and exposure blinding. To accommodate different neural network training routines, the pipeline can be configured to a high-speed validation mode using a three-camera setup at 30 frames per second, or a spatial context mode generating a six-camera surround view at 5 frames per second.

Data generation is split into two operational pipelines. GenSim-3 focuses on data augmentation by modifying environmental parameters such as weather, lighting, and object surfaces across real-world video segments at native 2MP resolution. VidGen-3 focuses on data creation, synthesising driving sequences from scratch by simulating environments, agent behaviours, and traffic logic without baseline video to patch geographic data gaps.

Helm.ai achieved the 2MP standard using a cluster of a few hundred GPUs rather than the thousands typically required for sub-HD video generation. This framework reduces the GPU infrastructure footprint for vehicle manufacturers and provides a method for compressing autonomous driving software onto mass-market on-vehicle compute chips.

Vladislav Voroninski, CEO and Founder, Helm.ai, said, "We are moving the industry from standard 'AI video' to authentic, hardware-accurate sensor emulation. By leading with a Full HD (2MP) standard and a 12-megapixel total aggregate capability per timestep, we have solved the resolution bottleneck that has historically limited the utility of generative AI in safety-critical systems. By optimising our compute architecture, we are giving our partners a high-performance platform to validate their autonomous stacks using synthetic data that perfectly matches the fidelity of their actual production sensors."

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Global automotive technology supplier Marelli has marked the 30th anniversary of its flagship electronics manufacturing plant in Guangzhou. Established in 1996 as Marelli’s inaugural manufacturing investment in China, the facility has transformed from a baseline assembly outpost into a major smart manufacturing and hardware-software validation centre.

Over the past three decades, the facility has expanded from a single operational production line with approximately 100 technicians into a 30,000-square-meter automotive electronics campus.

Today, the facility employs nearly 1,000 people and runs 66 active production lines, manufacturing components for both localised Chinese vehicle programs and global vehicle architectures.

The campus houses an adjacent, fully integrated Engineering Center that holds more than 100 registered patents. The manufacturing framework integrates high-precision assembly lines, automated optical bonding modules and site-wide rooftop solar arrays designed to manage factory energy overheads and lower operational carbon density.

The Guangzhou plant functions as a strategic industrialisation hub focused on low-cost, scalable architectures suited for the industry transition toward connected, software-defined vehicles (SDVs). The facility specialises in several high-growth hardware and display segments like advanced display solutions based on Mini-LED and MicroLED technologies. Additional key platforms include electronic control units (ECUs) for body and seat systems, zone control units, as well as digital cockpits, digital instrument clusters, and 5G telematics systems.

Ravi Tallapragada, President of Marelli’s Electronics business unit, said, “Our Guangzhou plant is a cornerstone of Marelli’s Electronics business in China and a powerful example of how innovation and advanced manufacturing can drive sustainable growth. Over the past 30 years, the team has continuously evolved its capabilities, developing advanced technologies and scalable platforms that address the rapid transformation of the automotive industry, building on long-standing collaboration with customers and partners. I’m proud of our team in Guangzhou and confident that the plant will continue to play a key role in shaping Marelli’s future globally.”

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