FORVIA HELLA KOLLEKT Research Project Advances Circular Vehicle Components

Germany-based FORVIA HELLA has introduced the KOLLEKT research project to accelerate the development of circular vehicle components, using automotive headlamps as the primary demonstration application. The three-year initiative expands on the outcomes of the NALYSES research project, completed in 2026, and aims to establish practical solutions that support a more circular automotive industry. By focusing on sustainable product design and efficient recovery processes, the project seeks to enable greater reuse of valuable materials while reducing waste throughout the product lifecycle.

Design for Circularity Drives Project Development

The KOLLEKT project is built around a comprehensive "Design for Circularity" concept that incorporates four fundamental strategies: Repair, Re-Use, Remanufacture, and Recycle. These principles are intended to improve how vehicle components are designed, processed, and recovered at the end of their service life. A central objective is the creation of a flexible disassembly cell capable of adapting to different product configurations, making industrial-scale dismantling more efficient and supporting broader implementation of circular manufacturing practices across the automotive sector.

AI, Robotics and Digital Twins Enable Automated Processing

One of the project's key technological developments is the integration of robots with AI-based data processing to automate product disassembly for reuse and recycling. Digital product twins will provide detailed component information, allowing precise, automated, and material-specific separation of assemblies. The workflow also includes optimized downstream sorting processes designed to remove contaminants and separate different plastic fractions. These recovered materials will subsequently undergo characterization before being prepared for mechanical recycling as well as partial chemical recycling, improving material recovery quality and supporting industrial-scale circularity.

Research Partners Supporting the Initiative

The project is being carried out through collaboration with several industry and research organizations, including BMW, Covestro, Geba, Fraunhofer IEM, Fraunhofer UMSICHT, and Paderborn University. Financial support is provided by the German Federal Ministry of Research, Technology and Space. This combination of industrial expertise, academic research, and government backing is intended to accelerate the development of scalable technologies that can strengthen circular economy practices throughout the automotive value chain.

Frequently Asked Questions

What is the FORVIA HELLA KOLLEKT research project?
The FORVIA HELLA KOLLEKT research project is a three-year initiative focused on developing circular vehicle components by applying Design for Circularity principles. Using automotive headlamps as a case study, the project combines AI, robotics, digital product twins, and advanced recycling processes to improve repair, reuse, remanufacturing, and recycling. Working with industrial and academic partners, the initiative aims to enable efficient industrial-scale material recovery while supporting a more sustainable automotive manufacturing ecosystem.