Motherson and PureCycle produce Class-A bumper with 30% recycled polypropylene

Prototype and testing

PureCycle and Motherson produced a Class-A surface automotive bumper prototype incorporating 30% PureFive® recycled polypropylene. The part was manufactured at Motherson’s Tuscaloosa, Alabama facility, with feasibility assessment and testing led by the Global Innovation Team in Germany. The component has undergone climate testing and mechanical-properties evaluation; results will be presented at Startup Autobahn Expo on July 2, 2026.

Material and traceability

PureCycle’s patented dissolution recycling process removes color, odor and contaminants from post-consumer polypropylene to produce PureFive® resin with properties similar to virgin material. PureFive® is third-party certified for recycled content, providing traceability and documentation intended to support OEMs and regulators in meeting recycled-content requirements.

Regulatory drivers

The collaboration directly addresses the EU End-of-Life Vehicles Regulation: pending final adoption, new vehicles must contain at least 15% recycled plastic by 2032 with a minimum 3% from end-of-life vehicles, rising to 25% and 5% respectively by 2036. Exterior components such as bumpers fall within the regulation’s scope.

Scale-up and next steps

PureCycle is expanding capacity for the automotive supply chain, with a dissolution recycling facility under development at the port of Antwerp expected to be operational in 2029 and a facility in Rayong, Thailand; both are stated as expected before 2030. Motherson and PureCycle plan further work on automotive-grade specifications, mass-production evaluation with PureFive®, increasing recycled content above 30%, and expanding into additional polypropylene exterior and interior applications.