Study finds benefits in auto parts reuse

According to a study from Worcester Polytechnic Institute (WPI) in Massachusetts, reusing automobile parts, such as engines, transmissions, bumpers, headlights and doors, across different vehicle types to repair vehicles offers environmental benefits and reduces the need for energy-heavy manufacturing processes without sacrificing product quality.

The study, “Quantifying the Greenhouse Gas Emissions (Carbon) Impact of Reusing Automotive Parts for Vehicle Repairs,” was led by Brajendra Mishra, the Kenneth G. Merriam Professor in mechanical engineering, and Hyunsoo Jin, a research assistant professor in the mechanical and materials engineering department, and sponsored by the Automotive Recyclers Association (ARA). The Manassas, Virginia-based ARA is a nonprofit organization that represents the interests of more than 4,500 professional automotive recyclers across the United States and in 17 countries.

The tests for the study were conducted at WPI’s Metal Processing Institute, a leading center for advancing materials science and sustainable manufacturing. The team assessed 10 common automotive components across three vehicle categories: sedans, SUVs and pickup trucks. Researchers analyzed data from 2015 models of the Toyota Camry, Jeep Grand Cherokee and Ford F-150, examining parts such as engines, transmissions, bumpers, headlights, doors, wheels, fenders, tailgates, hoods and door mirrors.

“This work provides clear, quantifiable evidence that reusing auto parts offers a practical way to reduce carbon emissions while improving supply chain resilience,” Mishra says. “By extending the life cycle of automotive components, we can significantly cut manufacturing-related emissions and decrease dependency on imported parts, making the industry more sustainable and self-sufficient.”

Using the Argonne National Laboratory’s Greenhouse Gases, Regulated Emissions and Energy Use in Technologies (GREET2) model and guidelines from the Environmental Protection Agency, the research team measured the carbon footprint of manufacturing new parts, including mining raw materials and producing steel, aluminum, copper, plastics, glass and rubber, WPI says in a news release about the study.

The study’s findings confirm that reusing auto parts dramatically reduces greenhouse gas emissions. For instance, reusing a single Toyota Camry engine can save more than 1,600 kilowatt-hours of energy (depending on the source) and prevent the emission of up to 1,760 kilograms of carbon dioxide, according to the report. These figures do not include the impact of transport emissions and end-of-life assessment.

“Further findings in our research demonstrate additional benefits for recycling rather than building from scratch,” Jin says. “The energy and labor required for transporting and manufacturing new parts are significantly higher than the energy used to dismantle cars and reclaim parts.”

Reclaimed auto parts also play a vital role in reinforcing the U.S. supply chain, the researchers say. By recovering and reusing parts from end-of-life vehicles, the industry can reduce demand for newly manufactured parts, many of which are produced overseas. This shift helps mitigate risks associated with global supply chain disruptions, ensuring more stable access to critical automotive components while promoting domestic economic growth, they add.

The WPI research team will present their findings at The Minerals, Metals & Materials Society (TMS) annual meeting March 23–27 in Las Vegas. The TMS is a professional association that connects minerals, metals and materials scientists and engineers working in industry, academia, and government positions around the world.