A first-of-its-kind study from Worcester Polytechnic Institute (WPI) shows that reusing automobile parts can greatly cut greenhouse gas emissions without sacrificing the quality of the products. The research, which examined commonly reused components such as engines, transmissions, bumpers, headlights, and doors across different vehicle types, highlights the environmental benefits of using reclaimed auto parts in vehicle repairs, which reduces the need for energy-heavy manufacturing processes.

“This work provides clear, quantifiable evidence that reusing auto parts offers a practical way to reduce carbon emissions while improving supply chain resilience,” said Brajendra Mishra, the Kenneth G. Merriam Professor in Mechanical Engineering. “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.”

The study, led by Mishra and Hyunsoo Jin, a research assistant professor in the mechanical and materials engineering department, titled “Quantifying the Greenhouse Gas Emissions (Carbon) Impact of Reusing Automotive Parts for Vehicle Repairs,” was sponsored by the Automotive Recyclers Association (ARA), a nonprofit organization that represents the interests of over 4,500 professional automotive recyclers across the United States and in 17 countries. The tests were conducted at WPI’s Metal Processing Institute, one of the nation’s leading centers 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.

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. Their findings confirm that reusing auto parts dramatically reduces greenhouse gas emissions. For instance, reusing a single Toyota Camry engine can save more than 1600 kilowatt-hours of energy (depending on the source) and prevent the emission of up to 1,760 kilograms of carbon dioxide. These amounts 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,” said Jin. “The energy and labor required for transporting and manufacturing new parts are significantly higher than the energy used to dismantle cars and reclaim parts.”