FORVIA showcases circular materials and advanced Interiors process know-how in JLR’s circular concept car

FORVIA showcased how its combined expertise in sustainable materials and advanced interiors processes can support the next generation of circular automotive design through its contribution to JLR’s new circular concept demonstrator.

• FORVIA demonstrates its ability to combine advanced circular materials and premium interiors expertise through its contribution to JLR’s Cornerstone project, supporting next-generation sustainable automotive design and engineering.
• The Cornerstone door panel significantly improves environmental performance with recycled content increased to 40%, recyclability to 58%, and CO₂ emissions nearly halved compared to current solutions. 
• The project showcases a closed-loop, design-for-circularity approach, transforming end-of-life vehicle materials into high-value interior applications while meeting premium quality and performance standards.
   

Forvia Interiors brought its process, injection and premium visible parts know-how together with MATERI’ACT’s expertise in advanced recycled and circular materials to develop a new, more sustainable door panel as part of JLR’s Cornerstone project.  It demonstrates how high-value interior applications can integrate increased recycled content while meeting demanding expectations in terms of design, performance and quality. Compared with today’s reference solution, the Cornerstone door panel delivers:

•    Recycled content increased from 15% to 40%
•    Recyclability improved from 11% to 58%
•    Cradle-to-gate CO2 emissions reduced from 580 to 277 kgCO2/vehicle

Combining circular materials innovation with advanced interiors process expertise

For the Cornerstone project, FORVIA Interiors and MATERI’ACT developed a new-generation interior and door panel solution combining FORVIA Interiors’ cut-and-sew, injection and part-integration capabilities with MATERI’ACT’s IniCycled-P recycled polypropylene compound and a TPO PP mono-material trim approach designed to improve recyclability and end-of-life recovery.

The project demonstrates how end-of-life vehicle materials sourced from JLR vehicles can be transformed into high-performance injection-moulded interior parts through FORVIA Interiors’ industrial and process know-how, combined with MATERI’ACT’s recycled materials expertise. This supports a closed-loop approach for the automotive industry while maintaining premium visible-part standards.

By leveraging FORVIA Interiors’ process, injection and integration know-how together with MATERI’ACT’s sustainable materials expertise, the teams developed an optimized part-and-material solution tailored to JLR’s sustainability ambitions.

Designing interiors with circularity in mind

The project reflects a broader shift within the automotive industry toward mono-material-compatible interior architecture designed to improve recyclability while maintaining premium standards for visible applications. It also illustrates FORVIA’s ability to combine materials innovation with industrial execution across the value chain.

PVC-free solutions, improved material compatibility and design-for-disassembly approaches contribute to facilitating future end-of-life vehicle recovery and recycling streams.

“With the JLR’s concept demonstrator, we are showing how FORVIA can combine advanced circular materials with strong interiors engineering and process know-how to deliver luxury visible applications with a reduced environmental footprint. This collaboration shows that circularity, design and industrial performance can go hand in hand,” said Thorsten Muschal, Executive Vice President FORVIA Interiors.

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