Articles tagged with "sustainable-manufacturing"
Dacia Hipster Concept cuts EV emissions by 50% with lighter build
The Dacia Hipster Concept is a minimalist electric vehicle designed to reduce its carbon footprint by 50% compared to current EV models. This ambitious goal is achieved through a lightweight construction that is 20% lighter than the Dacia Spring, extensive use of recycled materials such as Starkle panels and mass-dyed components, and a simplified manufacturing process that minimizes paint layers and production emissions. The car’s compact design includes a smaller battery optimized for urban and suburban driving, balancing sufficient daily range with lower environmental impact from battery production. The exterior features a single body color with only three painted parts, using mass-dyed materials to reduce paint waste and energy consumption. Its blocky yet balanced design maximizes compactness and functionality, with features like a full-width tailgate and integrated rear lights to reduce material use and costs. Inside, the cabin is space-efficient with vertical windows, a transparent roof section, and flexible seating that expands cargo capacity from 70 to 500 liters. The modular YouClip system allows
energyelectric-vehicleslightweight-materialsrecycled-materialssustainable-manufacturingbattery-efficiencycarbon-footprint-reductionWorld's first solar-powered furnaces unveiled to recycle luxury steel
Swiss company Panatere has unveiled the world’s first two solar-powered furnaces designed to recycle high-quality steel waste from precision industries such as watchmaking and medical manufacturing. Located in La Chaux-de-Fonds, these pilot systems use concentrated solar energy to melt stainless steel offcuts at temperatures up to 1,450°C (2,642°F) without fossil fuels. The larger furnace employs a 138-square-meter heliostat with 40 movable mirrors directing sunlight onto a 10-meter-wide concave dish, while the smaller system uses a 30-square-meter heliostat and a compact concentrator with about 460 mirrors. Both systems amplify sunlight intensity thousands of times to melt metal scraps, which are then recast into new ingots. Supported by research institutions under the Interreg France–Switzerland program, Panatere aims to refine this technology and open a full-scale factory by 2028, potentially producing up to 1,000 tons of recycled steel annually powered solely by solar energy
energysolar-energysteel-recyclingsustainable-manufacturinggreen-technologysolar-furnacerenewable-energyCreateMe innovates with robotic assembly, adhesion tech for the garment industry - The Robot Report
CreateMe Technologies Inc., based in Newark, California, has introduced two key innovations aimed at transforming apparel manufacturing: MeRA, an autonomous robotic platform for garment assembly, and Pixel, a proprietary micro-adhesive technology that replaces traditional sewing. MeRA enables software-defined, end-to-end garment construction, producing up to 250 garments per hour with twice the precision of manual sewing and at a speed 20 times faster. The first commercial application targets women’s intimates, offering fully autonomous bonded products designed for comfort, fit, and sustainability. The company plans to expand MeRA’s use to everyday apparel such as T-shirts, emphasizing flexibility and cost-competitiveness with offshore manufacturing. The Pixel adhesive technology bonds seams with precision less than 1mm wide, enhancing garment stretch, durability, comfort, and recyclability by allowing clean material separation—unlike traditional stitching or permanent adhesives. Pixel also supports performance features like moisture-wicking and thermal regulation, contributing to longer garment lifespans and smoother
roboticsrobotic-assemblygarment-manufacturingautomationadhesive-technologyapparel-industrysustainable-manufacturingVolvo ES90 Production Launches in Europe - CleanTechnica
Volvo Cars has commenced production of its new fully electric Volvo ES90 in Europe, marking a significant step in the company’s transition toward a fully electrified future. The ES90 features advanced 800-volt charging infrastructure, enabling super-fast charging, and offers a spacious interior designed with next-generation core computing powered by Volvo’s Superset tech stack. This technology allows the vehicle to evolve through continuous software updates, emphasizing Volvo’s commitment to safety, sustainability, and human-centric innovation. Produced at Volvo’s Chengdu plant using climate-neutral energy, the ES90 aligns with the company’s broader sustainability goals, including climate-neutral manufacturing and circular economy principles. According to Volvo’s Life Cycle Assessment report from July, the ES90 has one of the lowest carbon footprints among Volvo’s vehicles to date. The launch of the ES90 aims to reinvigorate consumer interest in Volvo’s electric offerings and demonstrates the brand’s ability to innovate while meeting evolving customer demands.
electric-vehiclesenergy-storagesustainable-manufacturingelectric-car-chargingclimate-neutral-energyautomotive-technologyrenewable-energyBen And Jerry's New Wastewater Plant Works A Lot Like The Human Body - CleanTechnica
Ben and Jerry’s ice cream factory in Vermont has implemented an innovative wastewater treatment system that mimics the human digestive process to manage its organic waste. Recognizing that ice cream production generates intense dairy waste unsuitable for conventional wastewater facilities—and that Vermont law prohibits sending organic waste to landfills—the company partnered with PurposeEnergy to develop an anaerobic digester system. This “constructed gut” processes high-strength organic waste and out-of-spec food products by harnessing microbial activity to convert the waste into methane gas, which is then captured and used to generate renewable electricity. The anaerobic digester, operational since December 2024, receives waste directly from Ben and Jerry’s production lines via a dedicated pipeline. It produces over one megawatt of electricity, enough to power approximately 1,300 Vermont homes, while also treating the residual water to remove particulates. This system exemplifies Ben and Jerry’s broader commitment to reducing environmental impacts across water, solid waste, energy, and CO2 emissions, aligning with their
energyrenewable-energywastewater-treatmentorganic-waste-managementmethane-reductionsustainable-manufacturingclean-energyJapan’s beam tech transforms forever plastics into reusable feedstock
Researchers in Japan have developed an innovative electron beam technique to recycle polytetrafluoroethylene (PTFE), commonly known as Teflon, with significantly improved energy efficiency. By combining moderate heat with electron beam irradiation, the method fully decomposes PTFE at 370 °C (698 °F), which is substantially lower than the 600−1000 °C required by conventional pyrolysis. This approach cuts the energy consumption for recycling from 2.8–4 MWh per ton to roughly half, making large-scale recycling of this durable fluoropolymer more economically viable. The process converts solid PTFE into gaseous oxidized fluorocarbons and perfluoroalkanes, which can potentially be captured and reused as raw materials in chemical manufacturing, promoting a circular economy for these persistent plastics. The research also found that high-temperature irradiation alters the internal structure of PTFE, enhancing its decomposition efficiency. PTFE belongs to the PFAS family, often called “forever chemicals” due
energymaterialsrecyclingelectron-beam-technologyPTFEfluoropolymerssustainable-manufacturingChina starts 1,000-ton plant to make green fabric with zero waste
China has inaugurated the world’s first 1,000-ton-scale ionic liquid cellulose fiber plant in Henan Province, developed by the Institute of Process Engineering at the Chinese Academy of Sciences. This facility marks a major breakthrough in sustainable textile manufacturing by using advanced ionic liquid technology to produce regenerated cellulose fibers with near-zero emissions. Unlike conventional fiber production that relies on toxic solvents such as carbon disulfide and N-Methylmorpholine N-oxide (NMMO), this new process employs stable, non-volatile ionic liquids that eliminate wastewater, waste gas, and solid byproducts, significantly reducing environmental pollution. The ionic liquids used are a novel class of salts that remain liquid near room temperature and possess tunable properties, allowing them to dissolve plant-based cellulose without harsh chemicals. This innovation not only cuts carbon dioxide emissions by an estimated 5,000 tons annually compared to traditional fossil fiber production but also achieves over 99% solvent recovery, underscoring its environmental benefits. After more than a decade of
materialssustainable-manufacturingionic-liquidsgreen-technologytextile-industrycellulose-fibersenvironmental-innovationApple commits $500M to U.S.-based rare earth recycling firm MP Materials
Apple has committed $500 million to MP Materials, the only fully integrated rare earth mining company operating in the United States, to bolster the domestic rare earth supply chain. This investment includes Apple's commitment to purchasing American-made rare earth magnets produced at MP Materials’ Fort Worth, Texas facility. The factory will focus on manufacturing neodymium magnets tailored specifically for Apple products, which will be distributed both nationally and globally to meet rising demand. Additionally, Apple and MP Materials will collaborate to establish a rare earth recycling facility in Mountain Pass, California. This plant will process recycled rare earth materials sourced from used electronics and industrial scrap for reuse in Apple devices. The partnership also aims to develop new magnet materials and processing technologies to improve magnet performance. This initiative aligns with Apple’s broader pledge to invest over $500 billion in the U.S. over the next four years and builds on its history of using recycled rare earth elements in its products since 2019.
materialsrare-earth-elementsrecyclingneodymium-magnetssupply-chainApplesustainable-manufacturingCarbon to candy: China tech could make food from captured carbon gas
Chinese scientists have developed an innovative enzyme-based method to convert methanol into sucrose (white sugar) without relying on traditional agriculture. This biotransformation system uses in vitro biotransformation (ivBT) to synthesize complex carbohydrates from methanol, which can be derived from industrial waste or chemically converted carbon dioxide. This breakthrough offers a sustainable alternative to sugar production that bypasses the need for land- and water-intensive crops like sugar cane and sugar beets, addressing environmental challenges and food security concerns amid climate change and population growth. The research, led by the Tianjin Institute of Industrial Biotechnology under the Chinese Academy of Sciences, achieved an 86% conversion rate of methanol into sugars, including sucrose and starch, using fast, low-energy enzymatic reactions. This method builds on earlier advances in converting CO₂ into methanol, effectively turning carbon waste into valuable food ingredients. Beyond sucrose, the system can produce a variety of carbohydrates such as fructose, amylose, and cellooligos
energycarbon-capturebiotransformationmethanol-conversionsustainable-manufacturingcarbon-neutralitychemical-engineeringFlash Ironmaking Hits Combustion Wall Amid Steel’s Decarbonization Shift - CleanTechnica
The article examines the prospects and challenges of flash ironmaking as a pathway for steel decarbonization amid shifting global steel demand, particularly due to China’s declining infrastructure growth. Flash ironmaking, developed from early 2000s research led by Professor Hong Yong Sohn, aims to revolutionize iron production by directly reducing fine iron ore particles rapidly, bypassing energy-intensive steps like cokemaking and pelletizing. This technology has demonstrated potential for significant energy savings—up to 60%—and carbon dioxide emissions reductions exceeding 50% compared to conventional blast furnaces, making it an attractive alternative for reducing steel’s environmental footprint. However, despite these promising attributes, the article highlights intrinsic limitations tied to flash ironmaking’s dependence on combustion to achieve the ultra-high temperatures required for rapid reduction reactions. The process typically relies on burning natural gas, biomethane, or hydrogen with pure oxygen, which inherently produces emissions and constrains the extent of decarbonization achievable. While flash ironmaking reduces emissions intensity
energysteel-decarbonizationflash-ironmakingindustrial-processesemissions-reductionsustainable-manufacturingclean-energy-technologiesWaste to painkiller? Bacteria convert plastic into paracetamol
Researchers at the University of Edinburgh’s Wallace Lab have developed a novel method to convert plastic waste into paracetamol (acetaminophen) using genetically engineered E. coli bacteria. This innovative process transforms terephthalic acid, a compound derived from polyethylene terephthalate (PET) plastic bottles, into paracetamol within 24 hours through a fermentation technique similar to beer brewing. Unlike traditional paracetamol production, which relies on fossil fuels and energy-intensive processes that emit significant carbon emissions, this biological method operates at room temperature and produces minimal emissions, offering a more sustainable and cost-effective alternative. The breakthrough hinges on a previously unobserved chemical reaction called the Lossen rearrangement occurring naturally inside living cells, enabling the bacteria to convert PET-based intermediates into para-aminobenzoic acid (PABA), a precursor molecule. By further inserting genes from mushrooms and soil bacteria, the researchers enabled E. coli to complete the conversion to paracetamol. This approach not only presents a promising
materialsbiotechnologyplastic-recyclingsynthetic-biologysustainable-manufacturingbioconversionpharmaceuticalsThe Moment to Make Automotive Steel More Circular Is Now - CleanTechnica
The article from CleanTechnica highlights the urgent need for the European Union to enhance circularity in automotive steel production. Despite the automotive sector being the EU’s second-largest steel consumer, only 6% of the steel used in cars comes from recycled scrap, far below the 56% average across all sectors. This low recycling rate is primarily due to contamination—especially copper from parts like wire harnesses—that occurs when old vehicles are shredded, rendering the steel unsuitable for reuse in new cars. The upcoming revision of the EU’s End-of-Life Vehicles (ELV) Regulation presents a critical opportunity to address this issue by introducing mandatory recycled steel content targets and quality standards. To unlock a market for higher-quality recycled steel, the article argues that EU policymakers should set a target of 30% recycled steel content in new cars by 2030, coupled with local content requirements to support European recyclers and reduce reliance on imported raw materials. Additionally, quality standards must be established to limit copper contamination in shredded scrap
energymaterialsautomotive-steelrecyclingcircular-economyEU-policysustainable-manufacturingUS turns recycled scrap into 3D-printed rocket parts with AI boost
robotmaterials3D-printingAIadditive-manufacturingrecycled-materialssustainable-manufacturingNew Jeep Compass Comes In Three Versions — Hybrid, PHEV, & Electric
electric-vehicleshybrid-technologyPHEVbattery-technologysustainable-manufacturingenergy-efficiencyelectrificationMaking EU State Aid Work for Clean Manufacturing
energyclean-technologyindustrial-decarbonisationEU-state-aidclimate-neutralityrenewable-energysustainable-manufacturing