A Second Life for Metal Components: TU Dresden Launches Upcycling Project

Researchers at the Technische Universität Dresden (TUD) are developing innovative production processes for the reuse and upcycling of metal components in the project "2nd Life Metal Components: A Pathfinding Project for Upcycling." The eight-year initiative is led by Prof. Alexander Brosius and Prof. Andrés Fabián Lasagni from the Institute of Manufacturing Technology. Funded with €13 million by the Werner Siemens Foundation, the project provides a broad research scope for a 25-member team.

As demand for metals in industrialized nations grows, so do anthropogenic stockpiles. This refers to the increasing amount of metals locked up in infrastructure and buildings for long periods. Given the scarcity of resources, traditional recycling methods—particularly the energy-intensive process of melting—are no longer sustainable.

The "2nd Life Metal Components" project seeks to avoid these processes by directly reusing existing metal parts through upcycling, thereby creating new products. This secondary utilization of existing raw material reserves is known as urban mining. These methods can significantly reduce energy consumption and conserve valuable resources. "Our approach makes it possible to save 90% of the energy typically required," emphasizes Prof. Brosius. "This project will set new standards in urban mining through the sustainable reuse of metals."

Laser-based technologies are employed to enhance the properties of recycled metals and to create customized sheets, known as "tailored blanks," with specific characteristics for targeted applications. This innovative method aims to improve ecological and economic efficiency in industries such as automotive manufacturing, foster circular economies, and support sustainability goals.

"Laser-based functionalization is another key to the success of this project," explains Prof. Lasagni. "It allows us to characterize and precisely adapt both the surface and volumetric properties of metals, enabling their reuse and enhancing their qualities for new applications."

The Werner Siemens Foundation
The Werner Siemens Foundation is a mixed family foundation under Swiss law, based in Zug. In its philanthropic efforts, it supports groundbreaking innovations and talented young individuals in engineering and natural sciences. The family council comprises descendants of Werner von Siemens and Carl Heinrich von Siemens, while a board of trustees oversees daily operations.

Contact:

Prof. Dr.-Ing. Alexander Brosius
Chair of Forming and Machining Technology
Institute of Manufacturing
Phone: 0351 463-37616
E-mail:

Prof. Dr.-Ing. Andrés Fabián Lasagni
Chair of Laser-based Manufacturing
Institute of Manufacturing
Phone: 0351 463-33343
E-mail: