Recycled plastic and innovative textiles for automotive use: ageing behaviour and industrial feasibility

automotive industry is undergoing a deep transformation, driven on one side by the transition toward electrification and the green revolution aimed at mitigating climate change, and on the other by rapid technological advancements and strong competitiveness among OEMs. In this context, companies are increasingly required to introduce innovative materials and functionalities in vehicles to meet regulatory demands and capture consumer interest. Within this framework, my doctoral thesis was structured around several research projects specifically focused on materials and technologies for automotive applications. The main study concerned the investigation of polypropylene compounds containing recycled polypropylene matrix, specifically post-industrial waste and post-consumer waste obtained through mechanical recycling. A complete validation of the materials was performed to assess the applicability of the compounds on commercial vehicles. Mechanical and thermal analysis, together with FT-IR spectroscopy and surface morphology investigation through scanning electron microscopy, were executed. The effect of thermal and UV ageing on the mechanical performance of the recycled compound was also assessed. In addition, two side projects were dedicated to innovative textile materials for automotive interiors. The first explored the effectiveness of antibacterial treatments applied to two different textiles materials destined for interior vehicle upholstery: a synthetic leather and a fabric. The antibacterial activity was tested before and after accelerated ageing and mechanical stresses, while SEM analyses were conducted to examine morphological changes induced by these conditions. The second project investigated the conductive properties of two flocked textiles intended for vehicle upholstery. Electrical performance was evaluated through DC measurements, supported by SEM analyses to characterize the distribution of conductive fibres within the fabric. Ageing and thermal stress tests were performed to assess durability. Furthermore, a functional prototype of a multitouch capacitive sensor was developed by integrating the conductive textiles into a microcontroller platform, demonstrating their potential for innovative automotive applications