Two Months After the ELV Regulation Took Effect, the First Case of End-of-Life Vehicle Plastics in a Mass-Produced Dashboard Has Been Completed

On August 13, 2026, the EU's revised End-of-Life Vehicles (ELV) Regulation (Regulation (EU) 2026/1738) officially entered into force, with full application scheduled for September 1, 2028. The new rules establish mandatory recycled plastic content targets for new vehicles: at least 15% from 2032 and at least 25% from 2037.

Automakers and Tier 1 suppliers are looking for answers. Meanwhile, the first case of integrating recycled plastics from end-of-life vehicles into the mass production of a large, visible interior component has already been completed. IniCycled-P (product model VP32M ELV), developed by FORVIA subsidiary MATERI'ACT, entered mass production for the Renault Master dashboard in July this year.

How Did 20% End-of-Life Vehicle PP Meet the Performance Requirements for a Visible Dashboard?

IniCycled-P is a polypropylene-based compound. Its specific formulation consists of 20% recycled plastics from end-of-life vehicles, 15% talc filler, and an impact modifier. The recycled material is supplied by GAIA, a subsidiary of The Future is NEUTRAL. The industrial chain runs from INDRA dismantling end-of-life vehicles, to GAIA sorting and processing the materials, to MATERI'ACT producing the compound pellets, and finally to injection molding the dashboard.

The biggest challenges in using recycled plastics for visible components are color variation and performance degradation. MATERI'ACT addresses these issues through homogenization and modification during compounding, using talc to improve dimensional stability and an impact modifier to compensate for the loss of toughness in recycled materials.

The results are promising: in airbag deployment tests, IniCycled-P performed comparably to virgin PP, and even better in some configurations. CO₂ emissions are 24% lower than those of conventional PP, reaching 1.47 kg CO₂e/kg. The material is fully compatible with standard injection molding processes, requires no equipment modifications, and can be integrated directly into existing production lines.

Why Start with the Commercial Vehicle Master Rather Than a Passenger Car?

The Renault Master is the largest light commercial vehicle in Renault's product lineup and belongs to a particularly cost-sensitive market segment. There are three practical considerations behind its selection as the first mass-production application.

• First, commercial vehicle dashboards have large surface areas and relatively simple structures. They generally allow greater tolerance for surface finish variations than passenger cars, making batch-to-batch differences in recycled materials easier to accommodate.

• Second, commercial vehicle users are highly cost-conscious, making potential cost reductions from recycled materials directly attractive.

• Third, the Master shares part of its dashboard supplier ecosystem with Renault's passenger car programs. Validating the process in a commercial vehicle first and then extending it to passenger cars provides a shorter development path.

The collaboration between MATERI'ACT and Renault extends beyond this project. Its sister product, NAFILean-R, combines hemp fibers with a matrix made from 100% recycled PP and is positioned for structural components. This aligns with the direction of using "100% recycled or natural materials" in the dashboard structure of the Renault 5 E-Tech. With IniCycled-P entering production for the Master, Renault's recycled-material initiatives now span both passenger cars and commercial vehicles.

A Roadmap for Recycled Plastics in Visible Components as the ELV Deadline Approaches

In the past, recycled plastics in automotive applications were mainly used in non-visible components, such as bumper energy absorbers, acoustic insulation, and trunk carpeting. Visible components have long been considered off-limits because of their demanding appearance and performance requirements. The use of IniCycled-P in the Renault Master dashboard opens a new path for recycled plastics in these applications.

JLR's Cornerstone project is also moving forward. In June 2026, FORVIA Interiors and MATERI'ACT jointly developed a new generation of door panels with high recycled content. From dashboards to door panels, and from commercial vehicles to luxury brands, multiple automakers are now validating the use of recycled plastics in visible interior components.

The application of IniCycled-P in the Renault Master demonstrates that a mass-production pathway for turning plastics from end-of-life vehicles into new-vehicle dashboards is feasible. For automakers and Tier 1 suppliers preparing for the ELV regulation, this is precisely where the case offers practical value.