Methods, Tools & Processes for Circular Economy

This study identifies and examines circular scenarios within the permanent magnet motor industry and provides planning strategies for PM motor recycling. The study adopted a two-stage research design, including exploration and evaluation phases and a SWOT analysis. Based on the findings, the study develops strategic strategies to help automotive companies transition to a circular economy.

The report describes the methodology of the Ecodesign process with a focus on environmental-, criticality- and circularity considerations concerning the RHODaS integrated motor drive (IMD). A Life cycle assessment (LCA) screening according to the ISO 14040/44 standard is performed for the environmental consideration. Within the project 30 % of the total IMD's Global Warming Potential (GWP) should be reduced. The methodology for circularity and criticality is roughly presented and still under development. Reference products and intended improved solutions, needed for later assessments, are described as far as possible. Furthermore, conceptual material/product selection matrixes, as part of the Ecodesign Guideline are presented.

The automotive industry is amidst an unprecedented multi-faceted transition striving for more sustainable passenger mobility and freight transportation. The rise of e-mobility is coming along with energy efficiency improvements, greenhouse gas and non-exhaust emission reductions, driving/propulsion technology innovations, and a hardware-software-ratio shift in vehicle development for road-based electric vehicles. Current R&D activities are focusing on electric motor topologies and designs, sustainability, manufacturing, prototyping, and testing. This is leading to a new generation of electric motors, which is considering recyclability, reduction of (rare earth) resource usage, cost criticality, and a full product life-cycle assessment, to gain broader market penetration. This paper outlines the latest advances of multiple EU-funded research projects under the Horizon Europe framework and showcases their complementarities to address the European priorities as identified in the 2Zero SRIA. Target of this paper is to introduce a family of European projects (EM-TECH, HEFT, MAXIMA, VOLTCAR and CliMAFlux), all following the target of high efficiency and low-cost electric motors for circularity and low use of rare resources. Especially, this paper will describe the latest advances of the respective projects as well as their complementarity to address the 2Zero strategy.

The RHODaS Webinar Series presents four interconnected sessions exploring the latest European research on next-generation electric powertrain technologies. Hosted by the RHODaS consortium under the Horizon Europe framework, funded by ‪‪the European Commission‬ and as part of the E-VOLVE Cluster, the webinar series will feature insights from the RHODaS, SCAPE, ‪‪@MaximaHEU‬ and EM-TECH projects, bringing together leading experts in power electronics, digital systems, and sustainability. Each webinar focuses on a specific technological domain critical to the electrification of transport — from component design and thermal management to digital intelligence and circularity. Together, they illustrate how European research is transforming electric mobility through efficiency, reliability, and environmental responsibility. 

This final session explores sustainability and resource efficiency in electric powertrains. Researchers from RHODaS, EM-TECH, SCAPE, and MAXIMA will present integrated approaches to life-cycle assessment, circularity, and material criticality, highlighting pathways toward a more sustainable and resilient e-mobility value chain.

Circular Design methodology is essential for sustainable industrial practices. This study provides a methodology with a Python-based computational tool that optimizes industrial products’ disassembly sequences, focusing on Design for End of Life (DfEoL) and Design for Disassembly (DfD) to promote Circular Design. The tool creates disassembly precedence graphs and shows the best disassembly path for target components, facilitating material recovery and environmental sustainability. The tool was applied to a case study on an Axial Flux Permanent Magnet (AFPM) electric motor. The approach provides a flexible and open access solution for optimizing product design within a Circular Design framework.

In the transition towards sustainable mobility, Circular Design principles are crucial. Electric Motors are subject to continuous innovation to improve efficiency, performance density and reduce externalities associated with their production. Therefore, the choice of technological solutions during design phase must guarantee optimal performance and minimal environmental impact throughout the entire product life cycle: production, use, and end-of-life. In the automotive sector, the use phase is particularly critical since the efficiency of the traction system is directly related to total energy consumption during the life cycle and, consequently, to its environmental impact. This research introduces a simulation-based approach to evaluate the use phase of an Axial Flux Electric Motor equipped with Permanent Magnets (AFPM). While providing high performance for electric traction motors, these magnets are composed of Rare Earth Elements (REEs), e.g. Neodymium, classified as Critical Raw Materials (CRMs) due to limited availability and environmental concerns associated with extraction and processing. However, the high torque and power density of this motor technology can potentially reduce the use of CRMs compared to other design solutions. The primary objective of this study is to show a preliminary scalable model that allows designers to evaluate motor performance under different design choices and use scenarios, defined through standard or custom driving cycles, providing immediate feedback in terms of environmental impact. The latter is evaluated by analyzing the powertrain’s energy consumption and efficiency using a road vehicle model, compiling the use phase inventory quickly, and simplifying access to information. This preliminary model thus serves as a decision-support system to balance performance optimization and environmental sustainability during the design phase. This work is part of a framework aimed at improving circularity of industrial products, particularly in the automotive industry. Incorporating environmental factors in design phases encourages innovative solutions that enhance efficiency and decrease reliance on limited resources.

Insights on the technology developed in the EU-funded project EM-TECH for using recycled permanent magnets

This poster describes an approach for a new end-of-life scenario for in-wheel motors at the Eco-Mobility 2024 Conference organized by A3PS.