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Design for Re-X

REMADE Announces $19.6 Million in New Technology Research to Accelerate the U.S.’s Transition to a Circular Economy - Institute Selects 14 Projects in Latest Round of Funding

The REMADE Institute is pleased to announce today that it has awarded $19.6 million in new technology research, selecting 14 new research, development and demonstration projects as part of the Institute’s latest round of funding.

Half of the projects involve research at the demonstration phase, responding directly to the nation’s need to meet multiple U.S. energy, environmental, and economic goals.

"These projects underscore the importance of manufacturing and materials innovations toward advancing a circular economy," said Dr. Christopher Saldaña, Director of DOE’s Advanced Materials and Manufacturing Technologies Office (AMMTO). "The partnership between DOE and the REMADE Institute serves as a conduit for catalyzing transformative practices that not only bolster America's manufacturing expertise but also accentuate our nation's commitment to environmental stewardship."

According to the U.S. Department of Energy, manufacturing accounts for 25% of U.S. energy consumption at a cost of approximately $150 billion. Based on data from the U.S. Environmental Protection Agency, industry is the single largest contributor to greenhouse gas emissions in the nation, at 30%.

REMADE Chief Executive Officer Nabil Nasr said these are just some of the main reasons why a circular approach to manufacturing — “make-use-reuse-remanufacture-recycle” — is so important, and why REMADE is dedicated to the adoption of a Circular Economy.

“A Circular Economy is imperative,” Nasr said. “It’s critical in reducing industry’s energy consumption and emissions in the race to net-zero by 2050. At the same time, a circular approach is vital to increasing U.S. manufacturing’s competitiveness, increasing the resiliency of the nation’s supply chain, and creating new clean economy jobs.”

REMADE Chief Technology Officer Magdi Azer said the Institute’s research seeks to increase circularity for four energy-intensive material classes: metals, plastics/polymers, fibers, and electronic scrap, or e-scrap.

“REMADE’s projects address multiple aspects of the Circular Economy, including systems analysis, circular design, remanufacturing and reuse, recovery and recycling,” Azer said. “These latest R&D projects will, for example, explore better ways to remanufacture cast iron components; remove contaminants from molten aluminum scrap; convert the midsoles of used shoes into a newer, more sustainable foam for footwear; develop machine learning tools to advance the sorting of textiles, design recyclable multilayer flexible packaging; and increase machine learning tools to better determine the state-of-health for used hybrid and electric vehicle batteries.”  

For more detailed information, read the full press release at the button below. A list of all REMADE R&D projects and their descriptions, including the 14 projects announced today, can be found at the “Research” button below.

REMADE Releases New Funding - Up to $20 Million in Funding to Accelerate the Transition to a Circular Economy

The REMADE Institute is proud to announce its sixth Request for Proposals (RFP), representing $20 million in investment to sustain U.S. manufacturing and accelerate the U.S.’s transition to a Circular Economy.

The Institute is seeking technology proposals for research, development and demonstration (RD&D) projects that develop and demonstrate tools and technologies consistent with REMADE’s goals to reduce energy and emissions; achieve better than cost and energy parity; and promote the widespread application of new enabling technologies across multiple industries. RD&D projects must align with one or more of the Institute’s focus areas: systems analysis and integration; design for reuse, remanufacturing, recovery and recycling (design for Re-X); manufacturing materials optimization; remanufacturing; and/or recovery and recycling.

R&D Project Spotlight: Vehicle Design for High-Value Recycling of Aluminum

The embodied energy of vehicles is increasing as energy‐intensive materials such as aluminum auto body sheet (ABS) are used to deliver improved performance. Unfortunately, the current system cannot effectively recycle automotive aluminum at end-of life (EOL) because the shredded aluminum is frequently contaminated with steel rivets, steel alloys, and copper wiring. As a result, 90% of auto shred aluminum is exported and downcycled.

In addition, the shift to electric vehicles (EVs) will increase the demand for high‐quality aluminum ABS and advanced high strength steels (AHSS) for light weighting, double the amount of copper wire (thereby increasing end-of-life contamination), and potentially reduce demand for vehicle castings that could utilize the lower quality scrap.

To address these end-of-life issues upfront, the R&D project team is developing a new design for recycling tool that considers how vehicle design, recycling system infrastructure, and sheet manufacturing process decisions impact factors such as EOL recycled content, closed and open‐loop recycling rates, greenhouse gas (GHG) emissions, and primary feedstock consumption and energy demand under different scenarios from 2020‐2050 (e.g. rapid deployment of EVs).

The tool will be integrated into the Argonne National Laboratory (ANL) GREET model, which is already widely used by the car industry to quantify environmental impacts. Once developed and implemented, this tool has the potential to reduce the consumption of primary steel and aluminum by 2.35 million metric tons (MMT) and 0.19 MMT, respectively.

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