Mercedes-Benz: Manufacturing EVs with Recycled Aluminium

Mercedes-Benz Trucks has launched the reECONIC project with Hydro supplying recycled aluminium components. The initiative builds on the eECONIC battery electric waste collection truck platform.

This involves Hydro providing low-carbon, recycled aluminium made from Hydro CIRCAL to Mercedes-Benz Trucks, for its reECONIC project.

According to Hydro, CIRCAL has one of the world's lowest carbon footprints for recycled aluminium. The material is produced using end-of-life automotive parts and building materials.

Electric vehicle applications

The reECONIC vehicle is based on Mercedes-Benz Trucks' electric waste collection platform. The truck incorporates recycled, natural and bio-based materials across various components.

More than 30 partners are involved in the project. The aim is to keep materials in closed loops while meeting safety, performance and quality standards for commercial electric vehicles.

Hydro has supplied 600kg of extruded parts for the reECONIC project. The components are made from Hydro CIRCAL, which contains a minimum of 75% post-consumer scrap content.

This enables customers to cut emissions while maintaining full flexibility in design, supporting manufacturers in reducing the environmental impact of their products at the material stage.

Achim Puchert, CEO of Mercedes-Benz Trucks, says: "Sustainability is an integral part of our strategy, which we are implementing in this project alongside strong partners. We are pursuing the clear goal of decarbonising our products."

Achim adds: "With the reECONIC, we are demonstrating a concrete path toward a more sustainable value chain in vehicle production."

End of life aluminium into EVs

As aluminium can be repeatedly recycled without losing its properties, it could make it suitable for circular manufacturing approaches in vehicle production.

The reECONIC project applies circular principles from material sourcing through to end-of-life recyclability. Hydro aims to demonstrate how aluminium can remain in circulation, supporting resource efficiency in European value chains.

Paul Warton, Executive Vice President of Hydro Extrusions, says: "The reECONIC project shows how circular design and low-carbon materials can go hand in hand. By delivering extruded profiles made from Hydro CIRCAL, we are transforming end of life aluminium scrap into high performance components for the next generation of electric vehicles.

"This is a concrete example of how circular aluminium solutions can help decarbonise mobility."

Trade fair exhibitions

Mercedes-Benz Trucks will exhibit the reECONIC vehicle at IFAT in Munich. The trade fair focuses on environmental technologies.

The reECONIC driver's cab will be displayed at the Mercedes-Benz Trucks booth. Cross sections of the vehicle and digital information will highlight the materials and components used.

Hydro will showcase the project at ALUFAIR 2026 in October. It plans to highlight its contribution to reECONIC as well as its broader portfolio of circular solutions.

The company plans to demonstrate demonstrate how low-carbon aluminium can enable circular manufacturing across industries, including mobility, building and construction.