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In May 2025 at Pacifico Yokohama and again in July at Aichi Sky Expo, the Automotive Engineering Exposition 2025 gathered the latest innovations in automotive and mobility technology. At the Honda booth, a new aluminum recycling technologyー"Complete Closed-Loop Recycling for Die-Cast Aluminum"ーwas introduced. Developed by Honda with technical support from the Honda Trading Group, this cutting-edge technology was presented alongside samples of the aluminum ingot. We spoke with Kunihiko Okazawa from the Light Metals Department of the Non-Ferrous Materials Division, and Hiroaki Funada of the Corporate Planning Department to learn more about the background, features, and future outlook of this initiative.
An Emerging Technology Introduced at a Leading Industry Event
The Automotive Engineering Exposition is a key venue showcasing advances in autonomous driving, electrification, and carbon neutrality. The event features real-vehicle exhibits, expert talks, and hands-on demonstrations, attracting professionals from across the industry.
Okazawa explains, "It's a valuable opportunity to connect with a broad range of people we don't usually interact with, from raw materials suppliers to parts manufacturers."
Among the many technologies Honda showcased this year, the newly developed closed-loop die-casting aluminum recycling technology was one of the highlights. The Honda Trading Group supported the project through technical collaboration during the development and testing phases. As the sole trading company within the Honda Group, Honda Trading supplies raw materials for global production and operates Honda Trading Aluminum, an affiliate with in-house testing facilities that have long supported various R&D collaborations with Honda.
Acting as a "test lab" for Honda, Honda Trading has accumulated valuable experience by working on technically challenging projects. This particular technology was developed jointly with Honda R&D. After the theme was selected, Honda Trading contributed technical support from the early validation phase.
Funada adds, "Because the goal from the beginning was to apply this technology to mass production worldwide, we also conducted overseas market research and economic feasibility studies as part of the development process, which lasted over two years."
Contributing to Honda's 2050 Goal: 100% Sustainable Materials
As automakers push for lighter and more environmentally friendly vehicles, recycling aluminum parts is increasingly important. Although aluminum is generally recyclable, die-cast aluminum scrap poses unique challenges. Scrap collected from the market often contains iron components that dissolve into the melt, requiring dilution with high-purity aluminum to reduce iron levelsーa process known as cascade recycling.
The new technology enables true closed-loop recycling by using only die-cast aluminum scrap (ADC12 and equivalent alloys). This is achieved through precise impurity removal and composition control during melting, eliminating the need for additional high-purity materials.
This innovation also supports the manufacturing of large structural parts used in gigacasting, essential for EV development. With tightening environmental regulations, especially in Europe, demand for high-quality recycled aluminum is expected to increase. This technology could help meet future supply challenges.
By reducing reliance on virgin aluminum and improving recycling efficiency, the technology not only lowers costs but also reduces CO₂ emissions, supporting Honda's vision of 100% sustainable materials by 2050.
Gunma Factory Support: From Lab-Scale Trials to Production Testing
The realization of this technology was made possible not only by Honda Trading's extensive expertise in aluminum manufacturing but also by the broad range of equipment at Honda Trading Aluminum's Gunma Factory. This facility includes small R&D furnaces, with capacities ranging from 1 to 500 kg, as well as large-scale production furnaces such as 7-ton and 10-ton rotary furnaces, which can be used for trial production runs. This range allows flexible testing tailored to partner needs.
Using this setup, more than 17 rounds of trial and error were conducted, spanning lab-level experiments to mass-production-scale tests. The focus was on material quality, including impurity removal, metal structure, and melt yield.Through this iterative process, the foundation for production-level application of this challenging technology was successfully established. One of Honda Trading's key strengths lies in conducting development, manufacturing, and quality testing in close proximity. This setup enables swift transitions from concept to execution.Funada notes, "Building on the validation work done at the Honda R&D lab, we provided hands-on testing support and detailed data analysis at the production site. This effort helped bring the technology closer to practical implementation and was a highly meaningful experience for us."
Honda Trading supports not only the mobility sector but also research and development efforts in other industries. For example, at the Gunma Factory, tests are underway to explore the possibility of turning dried factory wastewater into reusable resources. Besides aluminum recycling tests from non-automotive fields, Honda Trading also offers technical support and data analysis services across a broad range of industries. Okazawa remarks, "Looking ahead, we plan to engage even earlier in the processーstarting with raw material selection such as scrap sortingーand aim to provide more comprehensive solutions. We welcome inquiries from anyone interested."
Leveraging the experience gained through this collaboration, Honda Trading aspires to be a leading force in the aluminum recycling industry while continuing to contribute to sustainability in both the automotive sector and manufacturing as a whole.
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