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Air suspension systems are increasingly being used in cars. In production, metal can be replaced by plastics – if the material is suitable.

Air suspension systems are much more common in electric vehicles than in those with a combustion engine.

16:9

Polyamide

Kunststoff Werkstoffe

Dämpfer / Federn

Technische Kunststoffe

Sprung with Air, Engineered with Plastic

PA particle foam (EPA) has better properties than conventional polymer foams. Components made from EPA can also be overmolded with PA.

The relatively large-volume EPA core (left) can be overmolded. This extends the design freedom and enables large-volume but comparatively lightweight components (right).

Schaumspritzgießen

Schaumstoffe und Vorprodukte

Partikelschäumen

Schaumstoffe

Overmolding PA Foam with PA

In the injection molding production of the Polish cosmetics manufacturer Bell, only equipment and systems that use energy sparingly are purchased. Consumers are seen as part of the value chain.

Looks like glass, but does not break when it falls down. Bell already relied on PET for the production of cosmetics packaging at a very early stage.

Spritzgießen

Nachhaltigkeit

Polyethylenterephthalat

Trockner, Granulat-

Energieeffizienz

Spritzgießmaschinen

Kreislaufwirtschaft

Transparency in Production

Covestro has developed a new range of recycled polycarbonates. The plastics are obtained from end-of-life headlamps.

In the joint program initiated by German GIZ, the project partners develop value chains for materials recycled from end-of-life automotive headlamps.

Recycling

Automotive

Kunststoff-Recycling

Polycarbonat

Kunststoff-Rezyklat

Polycarbonate Made from Recycled Headlamps

The composite materials currently used in cars are often not recyclable. Mercedes has therefore recently started using mono-material sandwiches.

As a reference part for the natural fiber-based multi-material approach used in series production and the recyclable PET mono-material sandwich, the bending-loaded door pocket of the door panel of the Mercedes-Benz E-Class was used.

Verbundwerkstoffe / Werkstoffverbunde

Leichtbau

Faserverbundwerkstoffe

Not Only Lightweight,  But Also Recyclable

Audi and Fraunhofer IVV test solvent-based recycling process for PC/ABS blends. The recyclate obtained is also suitable for interior components.

Audi has set itself the goal of continuously increasing the proportion of secondary materials in the Audi fleet. For example, several components in the Audi Q6 e-tron are made from recycled materials. (Note: This does not apply to the PC/ABS described in the article).

Audi and Fraunhofer IVV make mixed plastic waste recyclable. The recyclate is also suitable for interior components.

Physically Recycled Post-Consumer Recyclate from End-of-Life Vehicles

PAs are often stabilized with copper- or halogen-containing additives in automobiles. Polymeric amines can be an alternative with fewer disadvantages.

The conditions in the engine compartment of electric vehicles are different from those of internal combustion engines. This presents opportunities not only for new materials, but also for other additives.

Stabilisatoren

Additive

Durable Even without Copper  and Halogens

The Hansgrohe Group is putting into operation the world‘s first plant for the electro-hydraulic fragmentation and material separation of electroplated plastic components.

True to the sustainability principle “Reduce, Repent, Recycle“, the handle of the hand shower of the product line Pulsify Planet Edition is made of recycled plastic.

Bautechnik, Sanitär

An Exemplary System

The German compounder hapego meets the Turkish materials manufacturer Politem – bout an intensive German-Turkish business relationship.

Politem produces more than 30 different types of plastic. The annual capacity is 60,000 t.

hapego and Politem: When a German compounder meets a Turkish materials manufacturer, it can lead to an intensive German-Turkish business relationship.

Compound

Schröder, Susanne

Länderspecial Türkei

“We Work together like a Good Blend”

The SPE Automotive Awards were presented for the 22nd time in 2024. Our series highlights the award-winning components – part 3 of the series.

If you want to see the innovation of the cooling profile, you need technical help. The secret is hidden in micro-nano structures that ensure a secure and tight connection between aluminum and plastic. 

Elektromobilität

Streifinger, Florian

Emerging Technologies and New Mobility

Reducing the cycle time increases productivity and reduces specific energy consumption. This can be reduced by using suitable compounds.

Polybutylenterephthalat

Elektronik

Steckverbinder

Material Modified, Cycle Time Reduced

Fakuma 2024 review: highlights in the materials sector

At first glance, the model looks like a standard skateboard. The exciting part is hidden inside.

Polyetherketon

Masterbatches

Polyoxymethylen

Farbstoffe und Pigmente

Messe Fakuma

Hochleistungskunststoffe

Polysulfone / Polysulfide

Sustainability Is Becoming  Less Important

PLA is rarely used in technical applications. The polymer is considered to be very sensitive to hydrolysis. A research project is now showing just how much.

Disposable cutlery and packaging are a classic area of application for PLA. In more demanding areas, however, the biopolymer is only used very rarely.

Polylactid

Biokunststoffe

Materialcharakterisierung

How Sensitive Is PLA to Hydrolysis?

Webasto relies on 80 percent sustainable materials, 40 percent weight savings and the use of solar energy for its new “EcoPeak” roof concept..

The new “EcoPeak” roof concept from the inside.

Webasto relies on 80 percent sustainable materials, 40 percent weight savings and the use of solar energy for its new “EcoPeak” roof concept.

Solar / PV

Kunststoffe, biobasiert

E-Fahrzeuge

„EcoPeak“ for Sustainable Mobility

Sustainability is also increasingly in demand for technical applications. More environmentally friendly PA variants are now available on the market.

Sustainability is also in increasing demand in technical applications.

Polyamides with Higher Sustainability

Thermoplastics from Lehvoss prove maximum resilience in e-bike frames during Xtreme Tech expedition in North Africa.

Endurance test for thermoplastics: The Moroccan desert is not only popular among bicycle fans, it is also an excellent testing ground for plastics. 

Mobilität

Endurance Test in Front of a  Spectacular Landscape

Part 1 of our series on highlights of the plastics museum: Phono combination Cockpit from Braun AG.

The phono combination “Cockpit” by Braun AG from 1970.

Polymethylmethacrylat

Music from the  Cockpit

The therapeutic product trains the senses through play using light, colors and shapes. PLEXIGLAS® Softlight ensures soft, glare-free light and a matte surface.

LiteScout | designed with PLEXIGLAS (PMMA) from Röhm GmbH | therapeutic product✓soft✓ glare-free light✓ matte surface ➤Watch video now!

Extrudieren (KU)

Compoundieren

LiteScout® supports visually impaired children with PLEXIGLAS® tokens

Ineos Styrolution announced that POGS has selected the Eco version of one of the company’s high-performance Novodur grades for a new range of headphones for children.

Polystyrol

ABS / ASA-Kunststoffe

Sustainable Headphones for Children

Algoliner has developed a photobioreactor with sustainability in mind. The PMMA tubes have a wall thickness of just 1 mm and are extruded directly at the point of use.

Although Algoliner‘s photobioreactor is 50 meters long and several meters high, the entire system appears almost weightless.

Thyrauer, Susanne

With an Extruder on a Field

A case study shows that the biodegradability of plastics in healthcare offers hardly any advantages. The use of bio-based raw materials also has its hurdles.

The rack seen  in nature with which it should have been in harmony after the completion of this study.