Follow PET Plastic Bottles as They’re Manufactured into Audi A3 Seat Fabric

Audi customers say they’re ready to switch away from leather upholstery in favor of recycled materials like the reused PET water bottles in the A3’s seat fabric.

Dan Carney, Senior Editor

October 11, 2021

10 Slides
Audi A3 seats.jpg
The soft fabric in these Audi A3 seats is made of polyester from recycled PET water bottles.Audi

As a synthetic fiber, polyester is proving particularly suitable for reuse in applications where the recycled material is indistinguishable from material made using virgin petroleum products. The seat fabric in the Audi A3 is an example where material recovered from polyethylene terephthalate (PET) plastic bottles is used to make the car’s upholstery.

PET is is a general-purpose thermoplastic polymer that belongs to the polyester family of polymers. These are good recycling candidates because polyester resins are known for their mechanical, thermal, chemical resistance as well as dimensional stability.

TWD Fibres GmbH, one of Audi’s partners in the process of creating automotive seats from recycled water bottles, lists five reasons to recycle PET:

  • Virgin polyester is a limited commodity

  • Recycled polyester saves CO2

  • TWD Fibres researches new applications

  • Recycled polyester equals virgin in quality

  • Recycling avoids waste and pollution

Audi has provided us a look at the process of going from bottles to seats from start to finish, so click through our photo gallery to see how it happens.

Can you guess how many bottles go into the creation of a pair of car seats? Check out Slide 10 to see how close you are to the real deal.

About the Author

Dan Carney

Senior Editor, Design News

Dan’s coverage of the auto industry over three decades has taken him to the racetracks, automotive engineering centers, vehicle simulators, wind tunnels, and crash-test labs of the world.

A member of the North American Car, Truck, and Utility of the Year jury, Dan also contributes car reviews to Popular Science magazine, serves on the International Engine of the Year jury, and has judged the collegiate Formula SAE competition.

Dan is a winner of the International Motor Press Association's Ken Purdy Award for automotive writing, as well as the National Motorsports Press Association's award for magazine writing and the Washington Automotive Press Association's Golden Quill award.

He has held a Sports Car Club of America racing license since 1991, is an SCCA National race winner, two-time SCCA Runoffs competitor in Formula F, and an Old Dominion Region Driver of the Year award winner. Co-drove a Ford Focus 1.0-liter EcoBoost to 16 Federation Internationale de l’Automobile-accredited world speed records over distances from just under 1km to over 4,104km at the CERAM test circuit in Mortefontaine, France.

He was also a longtime contributor to the Society of Automotive Engineers' Automotive Engineering International magazine.

He specializes in analyzing technical developments, particularly in the areas of motorsports, efficiency, and safety.

He has been published in The New York Times, NBC News, Motor Trend, Popular Mechanics, The Washington Post, Hagerty, AutoTrader.com, Maxim, RaceCar Engineering, AutoWeek, Virginia Living, and others.

Dan has authored books on the Honda S2000 and Dodge Viper sports cars and contributed automotive content to the consumer finance book, Fight For Your Money.

He is a member and past president of the Washington Automotive Press Association and is a member of the Society of Automotive Engineers

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