Renault A pillar interior trim made with LYB LyondellBasell polypropylene copolymer (PPC). A special effect compound is added to create the speckled appearance in combination with moulded textile texture, eliminating the need for covering.
A truck storage tray, produced from polypropylene (PP) by KraussMaffei using MuCell foaming technology. The foam reduces the density of the part, allowing it to become thicker and stiffer without adding weight. Foaming usually leaves surface marks as a result of the flow of the gas during moulding. It is most visible in black parts. The polymer is modified with additives to reduce the effect and surface texture added to eliminate the visual impact altogether. In this case, a textured in-mould label (IML) has been added to the centre (silver), completely concealing the black plastic beneath.
The front grille for the BMW iX is produced in a cleanroom environment, since any dust would be visible through the high-gloss polyurethane (PUR) finish. Produced in an integrated process, the component consists of a functional film that is back-injection moulded with polycarbonate (PC) and then flood-coated with 2-3 mm PUR. Engel developed the production cell.
Cross-section of a foam sandwich injection moulding. The white outer is virgin polypropylene (PP) and the black core is foamed recycled PP (rPP). The layers are formed by first injecting the white (the colour has been used to emphasis the technology in this case) and then injecting the black with chemical foaming agent (CO2). The black rPP forms a bubble inside the white, pushing into onto the surface of the mould. In application, the surface layer would be the same colour as the core to create a high quality visual surface. This example is a cross-section through the LimbicLife ergonomic chair seat. The process and tooling were engineering and optimised by Deckerform.
Renault interior door panel made with LYB LyondelBasell polypropylene (PP) with a chemical foaming agent added to produce a foamed part. This approach helps to save 15-20% weight. The texture is designed to eliminate the need for a covering, to save cost and ensure the part can be recycled end of life.
Renault interior door panel made with LYB LyondelBasell polypropylene (PP) with a chemical foaming agent added to produce a foamed part. This approach helps to save 15-20% weight. The texture is designed to eliminate the need for a covering, to save cost and ensure the part can be recycled end of life.
Audi loud speaker grille made with LYB LyondelBasell CirculenRecover 50% post industrial recycled (PIR) polypropylene (rPP). It has properties very close to that of virgin polymer for this application.
Exterior door side trim from the Dacia Duster made with LYB LyondelBasell CirculenRecover 20% post industrial recycled (PIR) polypropylene (rPP). A special effect compound is added to create the speckled appearance and eliminate the need for coating.
Interior automotive part in 100% recycled polypropylene (rPP). This grade from Burpol is optimised for both stiffness and impact strength, finding a balance between the two. It is only available in black or very dark colours.
An automotive door inner, produced from polypropylene (PP) using MuCell foaming technology. The foam reduces the density of the part, allowing it to become thicker and stiffer without adding weight. Foaming usually leaves surface marks as a result of the flow of the gas during moulding. It is most visible in black parts. The polymer is modified with additives to reduce the effect and surface texture added to eliminate the visual impact altogether. In this way, a monomaterial part is possible, without any coating or covering necessary.
An automotive door inner, produced from polypropylene (PP) using MuCell foaming technology. The foam reduces the density of the part, allowing it to become thicker and stiffer without adding weight. Foaming usually leaves surface marks as a result of the flow of the gas during moulding. It is most visible in black parts. The polymer is modified with additives to reduce the effect and surface texture added to eliminate the visual impact altogether. In this way, a monomaterial part is possible, without any coating or covering necessary.
An electric vehicle battery pack tray injection compression moulded in long glass fibre reinforced polypropylene (PP-LGF20) by Engel to demonstrate their large-format insert moulding capabilities.
Cross-section through a concept automotive seat by Johnson Controls and Camisma, manufactured with a combination of thermoforming and injection moulding. Sheets of continuous and unidirectional 12k carbon fibre and in-situ cast PA12 are combined with powder impregnated PA12 nonwoven recycled carbon fibre. They are placed into the mould and thermoformed, prior to back injection moulding of the rib structure using 30% long glass fibre filled PA12. Compared to a steel equivalent this structure saves 50% of the weight.
Concept automotive seat by Johnson Controls and Camisma, manufactured with a combination of thermoforming and injection moulding. Sheets of continuous and unidirectional 12k carbon fibre and in-situ cast PA12 are combined with powder impregnated PA12 nonwoven recycled carbon fibre. They are placed into the mould and thermoformed, prior to back injection moulding of the rib structure using 30% long glass fibre filled PA12. Compared to a steel equivalent this structure saves 50% of the weight.
Senoplast Senosan high impact acrylonitrile butadiene styrene (ABS) co-extruded with thermoplastic elastomer (TPE-TPS) and thermoformed into an automotive interior component. While the ABS provides impact strength and rigidity, the TPE contributes a tactile and durable surface.
Audi loud speaker grille made with LYB LyondelBasell CirculenRecover 50% post industrial recycled (PIR) acrylonitrile butadiene styrene blended with polyamide (rABS-PA). It has properties very close to that of virgin polymer for this application.
Natural fibre panels produced in a single step involving compression and injection moulding. Fibres are typically hemp, flax, jute or kenaf, mixed with polypropylene (PP) or polyethylene terephthalate (PET), polyester, which melt when heat and pressure is applied locking them in place. The over-moulding is with PP for integration and added stiffness.
Natural fibre panels used in automotive interior applications, such as this compressed nonwoven, are replacing glass filled and wood filled polypropylene (PP-GF and PP-WF) materials. They offer superior strength to weight combined with impact resistance. Fibres are typically hemp, flax, jute or kenaf, mixed with PP or polyethylene terephthalate (PET), polyester, which melt when heat and pressure is applied locking them in place.
Bio-based panels used in automotive interior applications, such as this compressed nonwoven natural fibre instrument panel topper, are replacing glass filled and wood filled polypropylene (PP-GF and PP-WF) materials. They offer superior strength to weight combined with impact resistance. Fibres are typically hemp, flax, jute or kenaf, mixed with PP or polyethylene terephthalate (PET), polyester, which melt when heat and pressure is applied locking them in place. Moulded by Weav3D.
Door impact bar test part for the Audi A4 consisting of several layers of woven glass fibre in a polyamide (PA-GF), nylon, matrix. The PA-GF organo is thermoformed into the shape of the mould and then back injection moulded with short fibre PA-GF. The result of a collaboration between Audi AG, Bond Laminates, the Institute for Composite Materials, Jacob Plastics, Lanxess, and KraussMaffei, this is a mass-producible composite suitable for safety-critical automotive applications. It is known as SpriForm and FiberForm.
Die casting in Zamak 5 by Adolf Föhl Germany. It is a shift lever that connects the shifter and the gear in ZF automotive gearboxes. Image Adolf Föhl Germany.
The Citroën C4 Cactus, with large, air-filled cushion bumpers in contrasting colours on the sides, front and rear. Injection moulded in scratch resistant, weatherproof and UV durable BASF Elastollan, the bumpers are left unpainted. Image Citroen.
A panoramic car roof headliner (ceiling trim), with integrated structural bracket. Instead of using steel, the traditional material for this type of application, BASF and Grupo Antolin collaborated to produce a n injection moulded structural bracket using BASF Ultradur polybutylene terephthalate (PBT), thermoplastic polyester. This material is lighter than steel and allows for greater design freedom and streamlined assembly in production. Image by BASF.
Press-moulded sandwich panel from ThermHex EconCore polypropylene (PP) honeycomb sandwich panel for automotive interior application. The PP core is sandwiched between PP skins and over-moulded with PP to create features on the edge. PP is used throughout, ensuring the product remains fully recyclable as a monomaterial.
Press-moulded sandwich panel from ThermHex EconCore polypropylene (PP) honeycomb sandwich panel, for automotive interior application. The PP core is sandwiched between PP skins ensuring the product remains fully recyclable as a monomaterial.
Looking inside a typical sun visor, which contains an injection moulded PC/ABS structure, and the cavity is filled with moulded expanded polypropylene (EPP), which provides a durable and lightweight body.
A composite bolster for Daimler by Valeo Thermal Systems, designed to replace a hybrid steel plastic moulding. The bio-based composite solution consists of flax reinforced polypropylene (PP-FF) woven unidirectional tape over-moulded with glass fibre reinforced PP (PP-GF). Compared to the hybrid steel weight is reduced by around 40% and the CO2 footprint reduced by around 40%, while part price is increased around 15%.
Nonwoven compressed flax fibre and polypropylene (PP-FF) panel for automotive interior applications. With heat and pressure, the PP fibre melts and bonds the flax fibres together to make a lightweight and impact resistant panel. Moulded by Weav3D.
Beltline stiffener door component manufactured by Weav3D and Braskem using a mix of unidirectional glass fibre and carbon fibre, combined with polypropylene (PP-GF and PP-CF). This component was designed to replace a carbon fibre reinforced polyamide (PA-CF), nylon, saving 23% weight and 50% cost. The PA-CF solution was originally designed to replace steel.
Part of a beltline stiffener door component manufactured by Weav3D and Braskem using a mix of unidirectional glass fibre and carbon fibre, combined with polypropylene (PP-GF and PP-CF). This component was designed to replace a carbon fibre reinforced polyamide (PA-CF), nylon, saving 23% weight and 50% cost. The PA-CF solution was originally designed to replace steel.
Injection moulded hubcaps that combine Oryzite (rice husk based bio-filler) and polypropylene (PP). It can be combined with many types of plastic. Using bio-filler reduces plastic consumption and can have some beneficial impacts on mechanical properties and price. However, it means the plastic is unlikely to be recycled end of life. As well as automotive, it is used in many applications already including packaging, product enclosures, pallets and household items. Image Oryzite.
A fabric lined polypropylene glass fibre (PP-GF) composite headliner, formed by low-pressure compression moulding. The PP-GF core creates a very lightweight and resilient structure.
A honeycomb development from ThermHex. Made in exactly the same way as the current EconCore technology, the wavy profile improves the stability of the honeycomb wall, enhancing strength to weight and compressive strength by up to 2x at low densities.
Sample of Roctool compression moulded polypropylene reinforced with recycled nonwoven carbon fibre (PP-CF40) to show print-though of fibre texture using various engraved Mold-Tech surface finishes.
Twill-woven glass fibre reinforced polypropylene (PP-GF60) textile. Before it is consolidated with heat and pressure to form a rigid composite, it is highly drapeable and so able to conform to the mould.
Injection moulded talc-filled polypropylene (PP-T20) using a mould with a surface texture that faithfully mimics leather including stitching. PP is cost effective and helps to maintain a cohesive material theme throughout an interior, because it can be used unpainted in many parts. For example, instrument panel (dashboard), door panel and pillar covers, which are in contact with one another. It may be combined with foam injection moulding (such as Mucell) to create lightweight structural parts with a TPO foil skin for the tactile surface. Using materials with similar chemistry enables higher rates of recycling.
Ducting made with low-pressure compression moulded nonwoven polyethylene terephthalate (PET), polyester fibre. Ribs are integrated into the moulding for added stiffness.
Low-pressure press-moulded polyethylene terephthalate (PET), polyester fibre, headliner. The surface that faces the passenger compartment is covered with a layer of polyester knit, bonded together with the nonwoven semi-structural backing during the compression process, taking the stack from around 30 mm to 5 mm.
Polyethylene terephthalate (PET), polyester, spacer fabric produced in a single Raschel warp knitting process, consisting of multi-filament faces separated by stiff mono-filament spacer yarns. This creates a highly breathable structure with very good stretch compression properties. It is used in a range of applications, from mattresses and upholstery to garments, footwear and electronics products.
Polyethylene terephthalate (PET), polyester, spacer fabric produced in a single Raschel warp knitting process, consisting of multi-filament faces separated by stiff mono-filament spacer yarns. This creates a highly breathable structure with very good stretch compression properties. It is used in a range of applications, from mattresses and upholstery to garments, footwear and electronics products.
Woven laminated airbag made with polyamide (PA), nylon, fibre and a fluid silicone coating. Alternatively, an impermeable film is laminated onto the nylon fabric to help maintain air pressure when inflated. The seams are welded for maximum resistance to tearing.
Commingled glass fibre thermoplastic composite preform, fabricated through tailored fibre placement (TFP) - a type of technical embroidery - in preparation for moulding with heat and pressure
Hyundai front bumper crash beam development, manufactured by CQFD using curved reactive thermoplastic pultrusion (CRTP) of continuous glass fibre reinforced nylon 6 (PA-GF), overmoulded with glass fibre reinforced black PA-GF
Press-formed automotive part, made up of patches of continuous glass-fibre reinforced nylon PA6, orientated to optimise strength, manufactured using Cetim’s high-speed thermostamping technique, named Quilted Stratum Process (QSP)
Press-formed automotive part, made up of patches of continuous glass-fibre reinforced nylon PA6, orientated to optimise strength, manufactured using Cetim’s high-speed thermostamping technique, named Quilted Stratum Process (QSP)
Cross-car beam produced by Elring Klinger with thixomoulded magnesium alloy assembled onto hydroformed aluminium alloy, over-moulded with 60% glass fibre reinforced polyamide (PA-GF60), nylon. This type of hybrid metal construction provides maximum strength to weight, whilst allowing design freedom for the integration of instrument panel, steering, airbags, hot and cold air, and all other necessary elements.
Car trunk lid trim by Fibriplast for automotive interior applications. A nonwoven fabric made up of flax fibre mixed with polypropylene (PP) and polyethylene terephthalate (PET), polyester, is low pressure compression moulded to make lightweight bio-based composite parts in a rapid cycle time.
Compression moulded Polestar seatback featuring Bcomp ampiTex and powerRibs flax thermoplastic composite, with over-moulded features on the backside to aid assembly.
Compression moulded automotive interior panel, with unidirectional fibre reinforced tape on the backside for added stiffness and impact resistance. The upper is a nonwoven made up of flax fibre and polypropylene (PP), compression moulded with unidirectional tape made up of flax reinforced PP. With this technique it is possible to mix all kinds of fibre reinforcement and thermoplastic matrix - the ingredients depend on the application requirements. Produced and moulded by Weav3D.
Automotive part made with natural fibre nonwoven mixed with polypropylene (NFPP) and compression moulded, followed by over-moulding with polypropylene (PP).
The Polestar seatback, compression moulded from Bcomp flax fibre reinforced polypropylene (PP-FF). The top layer consists of woven flax with white linen threads in a pattern unique to Polestar. The middle lays is a composite of flax and PP, and the inside layer consists of Bcomp power ribs, which provided added stiffness without adding significant weight.
The Polestar seatback, compression moulded from Bcomp flax fibre reinforced polypropylene (PP-FF). The top layer consists of woven flax with white linen threads in a pattern unique to Polestar. The middle lays is a composite of flax and PP, and the inside layer consists of Bcomp power ribs, which provided added stiffness without adding significant weight.
Compression moulded automotive interior panel, with unidirectional fibre reinforced tape on the backside for added stiffness and impact resistance. The upper is a mix of flax fibre and polypropylene (PP), compression moulded with carbon fibre and flax fibre tape (PP-CF and PP-FF). With this technique it is possible to mix all kinds of fibre reinforcement and thermoplastic matrix - the ingredients depend on the application requirements. Produced and moulded by Weav3D.
Bcomp's flax products are available in many different colours and formats, including dyed, woven, knitted and nonwoven. A harmony is struck between performance requirements, cost and aesthetics.
Libeco unidirectional woven flax fabric. It is used as fabric reinforcement in biocomposites, such as in combination with bio-based epoxy in vacuum infusion, or resin transfer moulding (RTM).
Electric GT Tesla front bumper in flax fibre and epoxy (EP-FF), made by infusion. It utilises Bcomp's ampliTex and powerRibs on the backside for added stiffness.
Biotex twill-woven bleached flax fabric, produced by Composites Evolution. It is used as fabric reinforcement in biocomposites, such as in combination with bio-based epoxy.
Biotex plain-woven flax fabric, produced by Composites Evolution. It is used as fabric reinforcement in biocomposites, such as in combination with bio-based epoxy.
Biotex biaxial flax fabric, with unidirectional untwisted yarns, produced by Composites Evolution. It is used as fabric reinforcement in biocomposites, such as in combination with bio-based epoxy in vacuum infusion, or resin transfer moulding (RTM).
Compression moulded composite, produced from embroidered glass fibre reinforced polyamide (PA), nylon, preform. The orientation of the fibres - tailored fibre placement (TFP) here produced by Nobrak - is optimised to give a balance between formability and performance.
Embroidered glass fibre reinforced polyamide (PA), nylon, preform. The orientation of the fibres - tailored fibre placement (TFP) here produced by Nobrak - is optimised to give a balance between formability and performance.
Structural sandwich panels with with aluminium honeycomb core. Typically, aluminium alloy 3003 or 5052 are used. Glass fibre reinforced epoxy skins provide excellent stiffness- and strength-to-weight. Aluminium faced honeycomb panels are relatively heavier, but offer excellent mechanical properties combined with a durable and decorative surface. Aluminium alloy 1050 is one of the most common sheet materials used where no special mechanical or chemical properties are required.
Composite automotive sandwich panel floor assembly for Zenos E10 sports car, with thermoplastic honeycomb core and carbon fibre reinforced polyurethane resin (PUR) skins, produced with spray-up compression moulding by Bright Lite Structures
A racing car monocoque survival cell (monocell), which protects the driver in the event of an accident. The capsule is made up of aluminium honeycomb sandwiched between multiple layers of carbon fibre reinforced epoxy (EP-CF). A mix of different carbon fibres are used. Unidirectional M46J and M55J are used in parts that require the highest stiffness; and T1000 and T800 for tension critical areas.
Carbon fibre reinforced epoxy (EP-CF) body system and monocoque for the Aptera solar powered vehicle. It is compression moulded from sheet moulding compound (SMC).
Cross-car beam produced by Elring Klinger using hydroformed aluminium alloy, over-moulded with 60% glass fibre reinforced polyamide (PA-GF60), nylon. This type of hybrid metal construction provides maximum strength to weight, whilst allowing design freedom for the integration of instrument panel, steering, airbags, hot and cold air, and all other necessary elements.
Lotus Elise S1 Chassis, launched 1995, manufactured by Hydro Aluminium from extruded 6063 and bent sheet 3105 aluminium alloy, riveted and bonded with 3M epoxy adhesive. The two-part adhesive is post-cured for enhanced strength. The bare chassis weighs just 68 kg.
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