Industrializing Electric Retrofit for Circular Mobility

The project develops an advanced electric retrofit model designed to transform existing internal combustion vehicles into electric mobility solutions through a circular and industrial approach.

Rather than promoting full vehicle replacement, the project proposes a regenerative pathway based on conversion, resource preservation and lifecycle extension. At its core lies a modular mechanical interface system – the “Ecoflange” – which enables the integration of an electric propulsion unit while preserving the original internal combustion engine block as a structural component.

This design approach is technically and strategically significant. By maintaining the homologated engine block and original structural geometries, the retrofit process does not alter the vehicle’s passive safety behavior. Impact absorption volumes and certified deformation zones remain unchanged, ensuring alignment with existing safety standards while minimizing invasive structural modifications.

The Ecoflange system is conceived as a scalable, modular solution adaptable to different vehicle categories, with an initial focus on two- and three-wheel vehicles and light commercial vehicles used in urban mobility and last-mile logistics. The methodology enables the reuse of structural and mechanical components that remain functional but environmentally outdated, thereby reducing material consumption and avoiding premature scrappage.

From an environmental perspective, the project applies circular economy and ecodesign principles by:

• extending the useful life of vehicles,

• reducing demand for new raw materials,

• lowering embedded emissions associated with manufacturing,

• minimizing industrial waste generation.

The retrofit process is designed not as an artisanal intervention, but as an industrializable and replicable system supported by standardized procedures and compliance pathways.

A central strategic component of the project is the implementation of Life Cycle Assessment (LCA) and Carbon Footprint methodologies. These tools will enable the scientific quantification of environmental impacts associated with vehicle conversion compared to new vehicle production. By defining system boundaries and measurable performance indicators, the project aims to provide evidence-based data to support industrial scaling, policy alignment and sustainability benchmarking.

Ultimately, the project positions electric retrofit as a structurally sustainable alternative within the electrification transition, accelerating decarbonization while preserving existing mechanical assets and promoting responsible resource management.