Repair and Recycling

Starting in 2026, European regulations will significantly tighten requirements for reparability, recyclability, and sustainable product design. Under the EU Repairability Directive, products may no longer be designed in ways that prevent them from being opened or repaired, or from being separated into single-material fractions. This shift brings new joining technologies into greater focus: traditional methods such as adhesive bonding, welding, and riveting often face limitations under these new requirements, as they can significantly hinder repair, reuse, or recycling.

At the same time, additional regulatory frameworks are fundamentally reshaping industrial practice. The Corporate Sustainability Reporting Directive (CSRD) requires companies to report on environmental and circularity-related aspects, while the upcoming Ecodesign for Sustainable Products Regulation (ESPR) sets requirements for sustainable product and process design and for demonstrating material efficiency and recyclability. These regulations are complemented by standards such as the CEN/CENELEC EN 4555x series on general ecodesign requirements and the ISO 20887:2020 standard on planning for disassembly and adaptability.

The commercial vehicle and rail industries, the construction sector (e.g., window and facade systems), and the passenger and special-purpose vehicle sectors are particularly affected, as public tenders increasingly require products to be recyclable. For companies, the message is clear: those who act early and rethink joining technologies can ensure regulatory compliance, gain market advantages, and maintain long-term eligibility for tenders.

HPCi^® (HeatPressCool-integrative) is a joining technology developed by Fraunhofer IWS, specifically designed to meet the new requirements for reparability, recyclability, and resource efficiency. HPCi^® analyzes, digitizes, and optimizes joining processes across the entire production chain, enabling future-ready, regulation-compliant manufacturing strategies.

The technology enables the creation of high-performance hybrid connections between metal, plastic, and ceramic – without additional aids such as adhesives, rivets, or screws. This not only reduces material use but also actively facilitates later disassembly, repair, and separation into single-material fractions. HPCi^® thus provides the foundation for regulation-compliant, sustainable, and cost-effective production processes, without compromising strength, sealing, or design freedom.

At the same time, the technology can significantly reduce process times compared with comparable adhesive bonding processes. Combined with the replacement of adhesives or other mechanical fasteners or seals, this creates substantial economic potential. Industrial application proves the concept: customers are already using our HPCi^® technology effectively in annual production volumes of up to the six-figure range.

• High-strength joints for automotive and aerospace applications
• Corrosion-resistant and long-term stability for plant engineering and the chemical industry
• Cost-efficient and scalable for packaging technology and white goods