Sustainable automotive materials: Innovations that carmakers and startups are making use of

The automotive industry has become increasingly conscious of the environmental repercussions associated with the use of conventional vehicle materials. For this reason, we have seen a surge in material innovation, aimed at developing sustainable and low-impact alternatives that retain a high degree of quality and function. From the use of cacti to cork, tomatoes to pineapples, and so on, automakers across all segments, from budget brands to luxury marques, and entrepreneurs are actively experimenting with new and alternative materials that are environmentally sustainable.

Injecting sustainability into interiors

While many of us solely focus on tailpipe emissions as a metric for how green a car is, let’s not forget the environmental impact of the sourcing and manufacturing of the multiple components that make up a car or SUV. For instance, synthetic leather, namely SofTex has emerged as a plausible replacement for genuine leather. This thermoplastic polyurethane is designed to resist wear, is easy to clean, and protects against the effects of spills making it the perfect seat material. It also weighs about half as much as real leather. Its manufacturing process generates around 99 per cent fewer Volatile Organic Compounds (VOCs) than conventional synthetic leather. And it doesn’t include any animal-based products.

Several manufacturers are also turning to the use of vegan leather made from cacti. BMW is collaborating with a startup called Desserto to source this cruelty-free certified leather, which is said to cut their emissions by 85 per cent since cattle rearing and processing cowhide both have a significant environmental impact. Mercedes-Benz is said to use the same in some of its vehicles.

Leather goods expert Carmen Hijosa’s groundbreaking idea of creating faux leather from pineapple leaf fibres has made the news. Piñatex™, the resulting non-woven textile from 25 million tons of annually harvested pineapple leaves, weighs merely a quarter of real leather while being two-thirds of the price. This initiative also helps repurpose what would have been discarded or burnt pineapple leaves and brings potential economic incentives to farmers and countries cultivating this spiky citrusy fruit. Piñatex, which is already used in footwear, bags, and clothing, has found applications in cars as floor mats. And now, manufacturers are looking into its use for car upholstery, particularly seats.

Among other cutting-edge materials being tested, a translucent smart surface material called Acella® Hylite stands out. This innovative material is claimed to dynamically adjust lighting based on weather conditions, ambient light levels, and even circadian rhythms as some sources say, ultimately enhancing passenger comfort and providing new opportunities for digital applications.

Enterprising car manufacturers have already incorporated a variety of natural fibres into their current range. These sustainable materials reinforce plastics, create foam, and replace harmful substances like fiberglass or oil-based materials. Examples of such natural fibres include soy foam, wheat straw, kenaf fibre, coconut fibre, and rice hulls. Additionally, there’s ongoing research into the feasibility of using leftover agave plant fibres from tequila production to produce more sustainable bioplastic parts, including wiring harnesses, HVAC units, and storage bins. Jose Cuervo, the popular tequila producer, is making impressive strides in fully utilising the agave plant’s components, harvesting some 200-plus tons daily. Beverage drinkers will soon find yet another cause to cheer to.

The exploration of fast-growing bamboo for interior applications is also gaining momentum. Bamboo, with its rapid maturation (3 to 5 years), compostability, and steel-like strength holds significant promise as a sustainable material option. We’ve seen Lexus use bamboo veneers in its vehicles, but we may also see its extensive use as parts of structural elements too.

Considerations for car exteriors

Meeting the stringent safety requirements for a car’s exterior poses challenges when it comes to adopting innovative material technology. That being said, automakers are actively exploring the potential of the advanced use of traditional materials like steel and aluminum, and non-conventional and exotic materials such as carbon fibre, alloys, and hybrid composites, to balance safety and sustainability.

One such material is plant-derived cellulose nanofibres or CNF. In 2016, Japan’s Ministry of the Environment in collaboration with 22 Japanese universities and automotive suppliers manufactured the Nano Cellulose Vehicle, a Lambo-esque car made entirely out of wood. This material is said to weigh about a fifth of steel while being five times as strong. And by incorporating this material in the car’s bodywork and tub, the vehicle’s weight is reduced to half that of a traditional automobile.