Car manufacturers are currently facing the challenge of making their products and production more sustainable in order to comply with sustainability requirements and legislation. For example, the latest draft legislation in the European Union requires a general use of 25% recycled material for plastic parts, of which 25% should be post-consumer recyclate (PCR). One way to make products more sustainable is to reduce the carbon footprint of fossil-based plastic parts. This can be achieved by using lightweight parts with minimum material input and therefore low density on the one hand, and recycled materials on the other. Particle foam parts have the potential to meet both requirements. Expanded polypropylene (EPP) parts are currently used in vehicles for their lightweight potential, insulating and energy absorbing properties. To achieve sustainable particle foam parts made from EPP, the recycled content must be increased while meeting material and mechanical property requirements. For this purpose, three simulated life cycles with two recycling loops were carried out on virgin EPP. The virgin material was processed to specimens in a steamfree process and then artificially aged to replicate automotive life cycle stresses. Then, the mechanical properties were evaluated, mechanical recycling was carried out and an EPP particle foam with 100% recycled content was produced and processed. Meanwhile, the material properties, such as thermal and chemical properties, were determined and analysed comparatively. After each recycling cycle the influences of different aging mechanisms and processing steps on the properties could be demonstrated. The molecular chain structure shows a clear dependence on the number of recycling steps, resulting in a more inhomogeneous distribution. Compression properties show a decrease of 13,7% after the first recycling step and 39,25% after the second recycling step. Overall, the recyclability of EPP material has been demonstrated, potentially allowing the use of higher levels of recycled content.