Covestro has launched a new range of post-consumer recycled (PCR) polycarbonate materials derived from end-of-life automotive headlamps, furthering its efforts to promote circularity in the auto industry. The material, developed through a joint initiative led by the German development agency GIZ (Deutsche Gesellschaft für Internationale Zusammenarbeit), includes contributions from automotive partners Volkswagen and NIO. TÜV Rheinland-certified, the PCR polycarbonate grades feature 50% recycled content and are now commercially available for automotive use.

Volkswagen and NIO are currently testing the material for integration into future vehicle models. According to Lily Wang, global head of Covestro’s Engineering Plastics business, the innovation supports the industry’s shift toward a sustainable, circular economy. “By offering high-quality PCR materials from end-of-life headlamps, we enable customers to meet regulatory demands and contribute to automotive plastics recycling,” Wang said.

Covestro is working closely with Chinese recycling firm Ausell and several automakers to create closed-loop systems for reclaiming high-value plastics from end-of-life vehicles (ELVs). This initiative focuses on enhancing recycling infrastructure and securing consistent supply chains for high-quality recycled content sourced from automotive waste.

The program has yielded practical solutions for collecting, processing and reintroducing headlamp plastics into the manufacturing cycle. These recycled materials meet the rigorous standards required for new automotive applications, including aesthetic quality and compliance with Vehicle Interior Air Quality (VIAQ) standards.

“This partnership demonstrates the value of cross-sector collaboration in accelerating circular economy efforts,” said Martin Hansen, regional director for GIZ in East Asia. “By uniting key industry players, we are building scalable recycling solutions and driving sustainable innovation in the automotive sector.”

The launch of these PCR polycarbonate grades comes as the global automotive industry faces mounting environmental pressures and stricter regulatory requirements. Legislation such as the European Union’s End-of-Life Vehicle Directive and China’s Extended Producer Responsibility (EPR) program are driving manufacturers to adopt more sustainable materials. Covestro’s new offering allows automakers to comply with these mandates while maintaining product performance and quality.

This development aligns with Covestro’s broader sustainability strategy. In recent years, the company has introduced polycarbonates with up to 90% recycled content and opened a dedicated mechanical recycling compounding line for polycarbonates in Shanghai. It has also begun offering chemically recycled, mass balance–certified polycarbonates sourced from post-consumer waste.

Through innovations like these, Covestro aims to reduce the environmental footprint of automotive manufacturing and support the industry’s transition to a more circular and sustainable future.

Covestro ranks among the world’s top producers of high-quality polymer materials and components. Through its innovative products, technologies and processes, the company contributes to greater sustainability and improved quality of life across a wide range of sectors. Covestro serves global customers in major industries including mobility, construction and housing, and the electrical and electronics field. Its advanced polymer solutions are also widely used in areas such as sports and leisure, telecommunications, healthcare and within the chemical industry itself.