MATERI’ACT: Advancing Sustainable Materials

MATERI’ACT came to light in November 2022 as the sustainable materials entity of FORVIA to develop low- and ultra-low-CO₂ materials from recycled, bio-based, and carbon-capturing compounds. This innovative approach reimagines what automotive materials can be, paving the way for more sustainable mobility.

Leveraging the foundation established by Faurecia with NAFILean back in 2011, in just two years, MATERI’ACT has introduced groundbreaking solutions such as NAFILean-R—a biocomposite that combines 20% natural hemp fibers with a 100% recycled polypropylene matrix. This combination creates a recyclable material that offers a 20% weight reduction compared to conventional plastics, contributing to improved fuel efficiency and lower emissions during vehicle use. Life cycle assessments show that NAFILean-R reduces cradle-to-gate CO₂ emissions by up to 90% compared to traditional materials, surpassing the industry average reduction of 50-70% reported for sustainable automotive plastics. Developed in partnership with Veolia and APM*, it meets the high standards for automotive interiors and is already in use, such as in the Renault 5 E-Tech, showing its feasibility for mainstream applications.

The entity incorporated Ocean Bound Plastics (OBP) into a concept car interior showcased at CES 2024. The material combines up to 20% OBP with bio-based fillers like oyster shell particles, achieving a 20% reduction in CO₂ impact. Sourced via a partnership with Plastic Odyssey, an NGO aiding local recycling efforts, the durable material was developed at MATERI’ACT’s R&D center in Villeurbanne, France.

This 7,500-square-meter facility near Lyon's La Doua campus includes offices and a materials prototyping and characterization laboratory. Also home to the entity’s headquarters, the space includes a 2,000-square-meter hub within the center dedicated to hosting innovative companies and startups focused on sustainable development and materials.

R&D and Partnerships Powering Progress

Part of the R&D behind these materials is the use of artificial intelligence (AI) to optimize low-CO₂ material development. By integrating data from partners and internal research, AI enables predictive modeling to forecast material performance, reducing the need for extensive physical testing. It also identifies energy-efficient manufacturing processes, minimizes waste, and ensures consistency, particularly with variable recycled inputs.

As European businesses race to meet the requirement of 25% post-consumer recycled (PCR) content (of which 25% from recycled End-of-Life Vehicles) in materials by 2030, MATERI’ACT positions FORVIA as a leader, surpassing these baseline standards. This success in sustainability is not achieved on our own and requires collaboration at every level. We work with partners throughout the entire value chain—from sourcing feedstock to developing advanced compounding processes—to ensure our materials meet customer needs and environmental goals. A notable example is our joint venture with PCR Recycling in North America, which focuses on sourcing and treating post-consumer plastics for use in sustainable automotive production across Canada, the US, and Mexico.   Another significant example is the Letter of Intent signed with Gree Electric Appliances to establish future joint ventures for developing, manufacturing, and selling recycled plastics in China.

Unsurprisingly, collaboration with OEMs is a cornerstone of MATERI’ACT’s approach. By engaging with OEMs early in product development, we ensure our materials can be seamlessly integrated into vehicle designs, empowering automakers to shrink their carbon footprints and accelerate the shift toward greener mobility. In 2023 alone, MATERI’ACT has won 12 awards with major automotive players. 

The Team Behind MATERI’ACT

Behind MATERI’ACT’s achievements is a committed team, currently close to 100 people strong. Each engineer, researcher, and data scientist brings a unique blend of expertise, creativity, and passion for sustainability. From developing cutting-edge recycled materials to overcoming the inherent challenges of variability in recycled feedstock, our team’s agility and determination are vital to creating stable, high-performing solutions that rival virgin materials. 

Broader Sustainability Innovations

MATERI’ACT isn’t the only place where FORVIA is making an impact. Our commitment to sustainability extends across multiple dimensions of automotive design and production. The Green Steel Seat Structure, developed with SSAB, uses fossil-free steel made by reducing iron ore with hydrogen and fossil-free electricity, eliminating the need for coking coal. This process cuts CO₂ emissions during steel production by 90% compared to conventional methods while maintaining the safety, strength, and durability required for automotive seating. Scheduled for full-scale production by 2026, it supports FORVIA’s goal of a 45% reduction on controlled CO₂ emissions by 2030.

Complementing this initiative is Auraloop®, a 100% recyclable cushioning material crafted from polyester fibers. This innovation replaces traditional polyurethane foam in seat pads, offering a solution that halves the carbon footprint of seat cushions. Alongside its environmental benefits, Auraloop® enhances thermal comfort and durability, ensuring that sustainability does not come at the cost of performance. 

Adding to these innovations, Ecorium offers a sustainable alternative to animal leather. Made from recycled plastics previously used as packaging materials and with hemp fibers, Ecorium achieves up to 90% lower CO₂ emissions compared to traditional leather. 

The Green Steel Seat Structure, Auraloop® and Ecorium set a new industry benchmark by reducing emissions during production and vehicle use. 

Driving Sustainable Progress

Transitioning to sustainable materials is essential for reducing the automotive industry's environmental footprint. Scaling these solutions presents challenges but also drives innovation. To support this shift, we are building resilient supply chains and ensuring sustainable materials are practical, competitive, and aligned with industry standards.

Every action, partnership, and innovation contributes to The Blue Effect, keeping us focused on aligning sustainability with performance and advancing the future of mobility in tangible, achievable ways.

* Joint Venture INTERVAL, an agricultural cooperative producing hemp and its co-products such as fibers.