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The United States Field Trial was chartered by the United States Council for Automotive Research/Vehicle Recycling Partnership (USCAR/VRP) with the objective of evaluating the feasibility and viability of collecting and recycling automotive polymers from domestic End-of-Life Vehicles (ELVs). European concerns regarding vehicle abandonment risks, decreasing landfill capacity, and disposal practices have resulted in the legislated treatment of ELVs in Western Europe. The emergence of attendant material collection schemes promoting material recycling may not apply to the free-market economic conditions prevalent in North America vehicle recycling infrastructure. Although ELVs are among the most widely recycled consumer products, 15-25% of their total mass is currently discarded with no material recovery, although their residue, when permitted, is a preferred landfill day cover in some areas.

A research project to determine the feasibility of utilizing polyethylene post-consumer automotive fuel tanks as a source of raw material was funded by Visteon, ExxonMobil, and was conducted by Brooks Associates. Brooks Associates launched this project in the last quarter of 2000 to demonstrate the feasibility of utilizing high-density polyethylene (HDPE) post-consumer automotive fuel tanks in combination with wood fiber to create a new material suitable as an automotive substrate. The concept for the project was based on proven technology that processes wood into fiber utilizing steam explosion. The steam explosion process was commercialized to form wood fiber as a raw material for ‘Masonite’. The product of the explosion process has also been made into a mat for further processing. This mat process is generally referred to as the ‘air-lay’ process.