Screws Replace Glue in a Quietly Radical Redesign
Mercedes’ vision of the future involves something unexpectedly old-school: screws. Part of Mercedes’ Tomorrow XX sustainability initiative is changing how automobile parts are constructed, beginning with vehicle headlamps. As opposed to using permanent adhesives to bond headlamp assemblies, Mercedes intends to use mechanical fasteners like screws. It’s how headlights were initially created as self-contained modules that could be individually repaired and replaced.
Sealed modern headlamps have become a common problem for car owners. If the lens develops a small stone chip or crack, it forces the replacement of the complete unit. The lens is glued to the headlamp housing, and removing it generally damages the whole thing. Using fasteners instead of adhesive means that technicians can replace the damaged part without destroying the rest of the assembly, significantly decreasing waste and reducing repair expenses.
Mercedes-Benz
Designing Components for Sustained Use
The headlamp redesign is just one element of Mercedes’ Tomorrow XX sustainability program. Less than two years since it began, the program has identified over 40 opportunities for improvement. Mercedes has started working with suppliers, recycling companies, and start-ups on how to rethink the construction and deconstruction of components.
One of the main focuses of the program is how individual components function throughout the lifetime of a vehicle. That includes making greater use of recyclable materials and designing fastening systems that will make deconstruction simple once a vehicle reaches the end of its service life.
Mercedes-Benz
Repairability Meets Sustainability Goals
Since each component is made of a single type of material, there is no need to segregate composite materials during recycling. This increases recycling efficiency and makes it more likely that parts will not be disposed of through incineration or landfills. The redesigned headlamps make use of nearly twice as much secondary recycled content as previous generations while reducing the carbon footprint by approximately 50%. Mercedes also hopes to establish a closed-loop recycling system where new headlamps are made from recycled materials from old headlamps.
They’re not stopping with headlights, either. Mercedes is testing thermoplastic rivets to connect door panels, enabling rapid deconstruction, and is studying the feasibility of using recycled airbags in engine mounts and recycled tire fiber in vibration dampers. Just goes to show that sustainability doesn’t always need innovative tech, but simply looking back to simpler times.
