BASF and its partners are set to present two technologies at K 2025 that allow for the recycling of polyamides from end-of-life vehicles. While metal recovery from decommissioned vehicles has been standard for decades, about 200 kilograms of plastic per vehicle are often incinerated. The new technologies aim to change this, especially with upcoming requirements from the End-of-Life Vehicle Regulation (ELVR). Pilot projects show how automotive waste can be used as material and returned to a closed cycle for the car industry.

BASF developed a chemical recycling process that recycles used and contaminated plastic parts – including used oil pans from ZF Group vehicles. The core of the process is depolymerisation, where the long polyamide chains break down into their original monomers. The caprolactam monomer obtained from PA6 is then purified. This removes impurities that would have remained with mechanical recycling and potentially reduced the material's quality and safety.

The material is then repolymerised into high-quality polyamide, which is processed into a compound suitable for demanding car industry components, closing the automotive-to-automotive loop.

"What used to be considered non-recyclable is now the starting point for high-quality new products," said Martin Scheuble, Team Leader Circularity Engineering Plastics at BASF.

ZF Group processed the recycled material into a chassis component for Mercedes-Benz. Tests show that depolymerisation allows for polyamide compounds that can be used without compromising performance or other chemical and physical properties.

"This project highlights the potential of recycled plastic - even for technically demanding applications - and underlines ZF's innovative strength in establishing sustainable material cycles," said Dr. Michael Lohrmann, Director Materials Technology at ZF.

Solvent-based recycling of shredder residue

A second pilot project focuses on recycling automotive shredder residue (ASR) – a mixture of materials left after the removal of mostly metals and glass. Close cooperation with a recycling company, using new sorting and processing technology, has allowed the polyamides to be extracted from this mixture in a largely pure form.

This polyamide fraction was the starting material for a solvent-based recycling process. In this process, the polymer chain is selectively dissolved with a solvent, purified and then reprocessed into PA6 compounds.

Poppelmann manufactured and tested a chain guide rail in series production at Mercedes-Benz using this technology.

"The project impressively demonstrates that solvent-based recycling is a practical alternative for plastics that are difficult to recycle mechanically. It makes an important contribution to the holistic circular economy - from the car back into the car," emphasised Steffen Meyer, Team Leader Production Technology at Poppelmann.

Life cycle analyses (LCA) confirm that both the solvent-based and depolymerisation technologies offer substantial CO2 emission savings compared to both conventional polyamide production and traditional plastic recycling methods like thermal recovery.

BASF offers a range of recycling solutions, stating that targets are achieved only if technologies are used in a complementary manner, depending on the type and availability of waste.

Jana Kragenbring-Noor, Head of Sustainability & Environmental Protection at Mercedes-Benz, explained, "Mercedes-Benz is committed to the use of secondary raw materials in its vehicles today and in the future as part of resource conservation and circularity. To continuously increase the availability of such sought-after secondary materials, the expansion of existing and new recycling technologies is essential."

"We are continuously improving the efficiency of physical methods such as mechanical and solvent-based recycling. In addition, we are convinced that complementary technologies such as chemical recycling, which includes depolymerization, pyrolysis and gasification, are necessary to further promote the circular economy and reduce the plastic waste that still ends up in landfills or is incinerated today, as well as the potential to obtain high-quality recycled plastics," explained, Dr. Martin Jung, President of BASF Performance Materials.

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CATL and the BMW Group have signed a Memorandum of Understanding (MoU) to expand cooperation on battery supply chain data exchange and decarbonisation. The agreement was finalised in Beijing during a visit by a German delegation including Chancellor Friedrich Merz.

The partnership focuses on pilot projects for cross-border data transfer under the Battery Passport framework. The companies will collaborate on carbon accounting methodologies and tools to calculate the carbon footprints of power batteries.

The initiative utilises Catena-X, a standardised automotive data ecosystem, to align technical standards and policy frameworks. By testing Battery Passport applications, CATL and BMW aim to meet China-EU regulatory requirements and establish global data standards for the battery industry.

The cooperation is intended to improve digital management and ensure compliance with EU market access regulations regarding green product competitiveness.

The strategic relationship between CATL and BMW began in 2012. Previous collaborations have covered battery production, research and development and supply chain sustainability. This MoU shifts the partnership from product-level cooperation to institutional coordination for electric mobility.

CATL stated its intention to continue cooperation with international partners to use technology for the global energy transition and the sustainability of the automotive sector.

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The BMW Group is accelerating the digital transformation of its manufacturing operations by embedding artificial intelligence deeply into physical processes. A central focus of this strategy is Physical AI, a concept that unites digital intelligence with machinery and robotics. This integration allows systems like humanoid robots to function effectively within live production environments. For the first time, this approach is being introduced in Europe through a pilot project at the company’s Leipzig plant, where humanoid robots will be tested in the assembly of high-voltage batteries and component manufacturing. This initiative builds on a previous deployment at the Spartanburg plant in United States, where valuable experience was gained and is now being used to refine and scale the technology.

Artificial intelligence is already embedded throughout the BMW production system, underpinning functions such as digital twins, AI-supported quality assurance and autonomous transport in intralogistics. A unified data architecture serves as the foundation for this intelligence, enabling real-time access to consistent and standardised information across all manufacturing locations. This infrastructure supports the deployment of digital AI agents capable of autonomous decision-making in complex environments. When these agents are paired with robotic systems, they give rise to Physical AI, which represents a significant evolution in production technology.

The company views humanoid robotics as a strategic addition to its automation portfolio. These robots are particularly suited to tasks that are repetitive, physically strenuous or present safety risks. By deploying them in such roles, the company aims to reduce physical strain on employees and enhance workplace conditions. To drive this forward, a Center of Competence for Physical AI in Production has been established to consolidate expertise and facilitate knowledge sharing across the organisation.

A structured process governs the evaluation of potential technology partners. Candidates are assessed against criteria related to maturity and industrial applicability, followed by laboratory testing using real production scenarios. Successful tests lead to limited deployments under actual factory conditions before advancing to full pilot phases. This methodology ensures that only thoroughly vetted solutions are integrated into series production.

The Leipzig pilot is being conducted in collaboration with Hexagon, a longstanding partner specialising in sensor technology and software. Following theoretical and laboratory evaluations, an initial deployment of Hexagon’s humanoid robot, AEON, took place at the plant in December 2025. A second test phase is scheduled for April 2026, with the full pilot set to begin in the summer of that year. The robot’s human-like design allows for the attachment of various tools and grippers, making it adaptable for multiple tasks in battery assembly and parts manufacturing.

Earlier work at the Spartanburg plant provided critical insights into the practical application of humanoid robotics. In partnership with Figure AI, the robot Figure 02 was deployed in body shop operations, where it handled the precise placement of sheet metal parts for welding. Over 10 months, the robot supported the production of more than 30,000 vehicles, operating in 10-hour shifts and handling over 90,000 components. The pilot demonstrated that humanoid robots could perform high-precision tasks reliably and safely in a live production setting. It also highlighted the importance of early collaboration with teams responsible for IT infrastructure, safety and logistics. Seamless integration into the existing automation ecosystem was achieved through standardised interfaces, and employee reception was notably positive, aided by transparent communication from the outset.

The success of these initial deployments has paved the way for further collaboration. BMW and Figure are currently exploring additional applications for the next-generation Figure 03 robot, continuing to build on the foundation established in both United States and Europe.

Milan Nedeljković, Member of the Board of Management of BMW AG, Production, said, “Digitalisation improves the competitiveness of our production – here in Europe and worldwide. The symbiosis of engineering expertise and artificial intelligence opens up entirely new possibilities in production,”.

Michael Nikolaides, Senior Vice President Production Network, Supply Chain Management at BMW Group, said, “Our aim is to be a technology leader and to integrate new technologies into production at an early stage. Pilot projects help us to test and further develop the use of Physical AI – that is, AI‑enabled robots capable of learning – under real-world industrial conditions. The successful first deployment of humanoid robots at our BMW Group plant in Spartanburg in the USA proves that a humanoid robot can function not only under controlled laboratory conditions but also in an existing automotive manufacturing environment.”

Michael Ströbel, Head of Process Management and Digitalisation, Order to Delivery at BMW Group, said, “We are delighted to deploy a humanoid robot for the first time in a pilot project at a plant in Germany. Following evaluation by our Center of Competence for Physical AI in Production, tests were carried out in the laboratory and at Plant Leipzig at the end of last year. This year, our focus is on step‑by‑step integration into our production system to explore a wide range of applications. The emphasis is on researching multifunctional use of the robot in various production areas such as battery manufacturing for energy modules and component production for exterior parts. With Hexagon, we have found a proven long‑standing partner with a highly innovative approach to humanoid robotics for this project.”

Felix Haeckel, Team Lead CoC Physical AI for Production, said, “At our new Center of Competence for Physical AI in Production, we are pooling our expertise to make knowledge on AI and robotics widely usable within the company. In recent years, we have built up an international team of experts that, in addition to in‑house research and programming, is dedicated to the gradual integration of AI into the existing production system. At the same time, our team in Munich is driving its own robotics research to set up, support and further develop pilot projects in the field of Physical AI at our plants.”

Arnaud Robert, President of Hexagon Robotics, said, “We are very pleased to be working with the BMW Group to advance the use of humanoid robots in real‑world environments.”

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The ePlane Company has inaugurated a 60,000 sqft integrated prototyping and testing facility at the IIT Madras Discovery Campus. The site is the first dedicated plant in India for the serial production of electric vertical take-off and landing (eVTOL) aircraft, marking a transition from laboratory research to industrial manufacturing.

The facility was opened by Professor V. Kamakoti, Director of IIT Madras. It will serve as the engineering centre for the e200X, a compact electric air taxi designed for urban environments.

The site includes units for composite fabrication, electric powertrain assembly, and avionics testing. It also features a Ground Test Vehicle (GTV) facility to support subsystem validation. The ePlane Company is currently working with the Directorate General of Civil Aviation (DGCA) to establish the certification and flight-testing framework for the e200X.

Key technical specifications of the e200X include:

• Footprint: A 8m x 10m design, intended for rooftop-to-rooftop operations.
• Efficiency: Synergistic Lift technology providing 35 percent higher energy efficiency.
• Deployment: Initial commercial application as an air ambulance to reduce medical transport times.

Incubated at IIT Madras, the company utilises the institute’s infrastructure and engineering talent. The ePlane Company has also established partnerships with technology firms including NVIDIA, AWS, Dassault and CADFEM-Ansys for simulation, cloud infrastructure and avionics.

Prof. Satya Chakravarthy, Founder and Technical Lead of The ePlane Company, said, "This facility is the engine of our commercial future. With the support of IIT Madras, we have built a space where we can fulfill our vision of making flying as common and affordable as taking a taxi. This isn't just about moving people; it’s about adding another layer of transport to the future of human mobility.”

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UK-headquartered Wayve, a developer of embodied AI for autonomous driving, has raised USD 1.2 billion in a Series D investment round. The funding brings the company’s valuation to USD 8.6 billion and marks a transition from research to the commercial deployment of its AI platform.

The round was led by SoftBank Vision Fund 2, Eclipse and Balderton. New participants include the Ontario Teachers’ Pension Plan, Baillie Gifford and the British Business Bank. Strategic investors Microsoft, NVIDIA and Uber also participated alongside automotive manufacturers Mercedes-Benz, Nissan and Stellantis.

Wayve’s platform uses end-to-end AI, which runs on onboard vehicle compute and embedded sensors. Unlike traditional autonomous systems, it does not require high-definition maps or location-specific engineering. This architecture allowed the company to test its technology in more than 500 cities across Europe, North America and Japan without city-specific fine-tuning.

Key milestones include:

• 2026: Launch of robotaxi trials on the Uber network, starting in London.
• 2027: Availability of passenger vehicles equipped with Wayve’s ‘AI Driver,’ featuring L2+ capability for steering and navigation under supervision.
• Licensing: Wayve will license its software to automakers, allowing for brand-specific customisation of driving models.

Uber has committed capital to support the deployment of Wayve-powered robotaxis in more than 10 markets globally. Under this agreement, Wayve provides the AI Driver for L4-capable vehicles, while Uber manages the fleet operations.

Alex Kendall, Co-Founder and CEO, Wayve, said: “With USD 1.5 billion secured, we are building for a total addressable market that spans every vehicle that moves. Autonomy will not scale through city-by-city robotaxi deployments alone. It will scale through a trusted platform that automakers and fleets can deploy globally and improve continuously. This investment accelerates our path to widespread commercial deployment and positions us to build the autonomy layer that will power any vehicle, anywhere.”

Dara Khosrowshahi, CEO, Uber, said, “We are very proud to continue to deepen our partnership with Wayve, with plans to deploy together in more than 10 markets around the world. Wayve’s powerful end-to-end approach is purpose-built for scale, safety, and effectiveness, and we’re excited to work with them across multiple OEMs and geographies, which we’ll share more about soon.”

Satya Nadella, Chairman and CEO, Microsoft, added,  “Wayve is pushing the frontier of embodied AI for autonomous driving, and Azure supports the scale, reliability, and safety needed to bring that innovation into the real world. Through our partnership and investment, we’re helping accelerate the path from breakthrough research to scaled commercial deployment with automakers worldwide.”

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