The RHODaS project has released a new technical deliverable examining the sustainability performance of integrated electric powertrains for heavy-duty vehicles. The publication, “Environmental, criticality and circularity assessment of materials systems and components”, presents a comprehensive life-cycle analysis of the project’s Integrated Motor Drive (IMD) developed for electric trucks.

The study, conducted by Technische Universität Wien, evaluates how design choices and circular strategies can reduce environmental impacts and dependence on critical raw materials across the full lifecycle of the system. The IMD integrates four key components – inverter, electric motor, gearbox and heatsink – into a compact architecture designed to support efficient and durable zero-emission freight transport.

Using a cradle-to-grave life cycle assessment approach based on ISO 14040/44 standards, the research assessed raw material extraction, manufacturing, transport, operational use and end-of-life scenarios. Results show that the RHODaS prototype achieves a modest but meaningful efficiency improvement of about 0.4% compared to the baseline configuration. Over the long operational lifetimes typical of heavy-duty trucks, even small efficiency gains translate into measurable reductions in energy consumption and associated emissions.

The most significant sustainability benefits, however, arise from circular design strategies. The modular architecture of the inverter and improved accessibility of key components allow easier repair and maintenance, extending the system’s expected lifetime by around 50%. This reduces the need for replacement units and lowers cumulative material demand and manufacturing impacts.

The assessment also compared several end-of-life scenarios, including conventional recycling, remanufacturing and advanced circular business models such as leasing. Results show that reuse and remanufacturing outperform recycling in reducing demand for critical raw materials. In optimised circular scenarios, the need for virgin neodymium used in permanent magnets can be reduced by up to 90%, demonstrating the importance of keeping high-value components in controlled reuse loops.

Beyond technical design, the study highlights the role of circular business models in enabling large-scale resource efficiency. Approaches such as leasing or “product-as-new” models increase product return rates and facilitate remanufacturing, improving both environmental performance and supply security.

Read the full deliverable from the RHODaS’ website.