3 Innovations in High Performance Engineering Plastics New

Corporate Communications, Leverkusen, April 2006

April 11 & 12, 2011

Thomas Babl

LANXESS Hong Kong Ltd.

3rd International Conference, EPC3, for S & SE Asia on

Innovations in High Performance Engineering Plastics

New Polyamide-based Solutions for Structural Parts and

Blow Molded Articles

Table of Contents

1. LANXESS Introduction

2. Reducing Weight and Costs:

1. Metal Replacement through Durethan® & Pocan® High Modulus

2. Introduction to Hybrid Technology

3. Structural Composite Solutions

3. Increasing Fuel Efficiency and Decrease Emissions:

1. Engine Trends

2. New Blow-moldable Materials for Modern Cars and 2-Wheelers

4. New Developments in the Area of CAE Technologies

Table of Contents







1. Engine Trends



Corporate Communications, Leverkusen, April 2006

Spinned off

LANXESS products Performance Polymers - Semi-Crystalline Products (SCP)

Advanced Intermediates - Basic Chemicals (BAC)

Performance Polymers - Butyl Rubber (BTR)

Performance Polymers - Polybutadiene Rubber (PBR)

Advanced Intermediates – Saltigo (SGO)

Performance Chemicals - Functional Chemicals (FCC)

Performance Polymers - Technical Rubber Products (TRP)

Performance Chemicals - Inorganic Pigments (IPG)

Performance Chemicals – Leather (LEA)

Performance Chemicals - Ion Exchange Resins (ION)

Performance Chemicals - Material Protection Products (MPP)

Performance Chemicals - Rhein Chemie (RCC)

Performance Chemicals – Rubber Chemicals (RUC)

As of: December 31, 2009 / Employees worldwide

Employees according to segments

Performance Polymers 4,375

Advanced Intermediates 2,858

Performance Chemicals 4,675

Worldwide over 14,335

incl. Service units

Our staff is at home all over the world

People all over the world are contributing towards the success of our company. Different perspectives

encourage people to think outside the box and search for new and innovative solutions together.

Isithebe

Thane

Qingdao

Toyohashi

Brunsbüttel

Leverkusen

Mannheim

Filago

Port Jérôme

Uerdingen

Dormagen Antwerpen

Marl

Chardon/OH

Sarnia/Canada

Orange/TX

Lerma

Bitterfeld

Porto

Feliz

Zaraté

Vilassar de Mar

Rustenburg Sydney

Wuxi Baytown/TX

La Wantzenau

Branston

Zwijndrecht

Hamm-Uentrop

Madurai

Bushy Park/SC

Merebank Newcastle

Shanghai

Burgettstown

Weifang

Birmingham/NJ

Cabo de Santo Agostinho

Triunfo

Duque de Caxias

Production Sites

LANXESS is one of Germany’s most important providers of polymers and chemicals

Employees worldwide (as of: 2010-12-31)

Global orientation

14,648

Around 45 sites

24 countries

Performance Polymers

Advanced Intermediates

Performance Chemicals

Portfolio

Sales in the year 2010 EUR 7.1 bn

Facts and Figures

Grouping business activities into 3 segments

Reporting

structure

Key data year

2009 in €

Sales

2.388 bn.

Sales

1.104 bn.

Sales

1.530 bn.

Advanced

Intermediates

Performance

Chemicals

Performance

Polymers

Performance Polymers - Semi-Crystalline Products (SCP)

Durethan®

PA6

PA66

Co-PA, PA6I

Pocan®

PBT

PET

and blends

Typical applications in LANXESS Durethan® (PA6, PA66, Co-PA, amorphous PA)

Electro/ Electronics Sports and Leisure

Packaging

Tools

Transportation

Typical applications in LANXESS Pocan® (PBT, PBT+PET, PBT+ASA, PBT+PC)

Electro/ Electronics

Automotive

Table of Contents







1. Engine Trends



Example: CO2 emissions of OEMs in Europe and targets for 2012

100 kg weight reduction means approx. 0.5 l/100 km less fuel consumption

or approx. 13 g/km less CO2 emissions

Source: Polymotive

CO2 emissions g/km

Current average for all cars

0 50 100 150 200

Failed proposal from EU

Commissioner Stavros Dimas

EU directive by 2012

Materials breakdown for the Volkswagen Passat

5%4%3%

53%

6%

14%

13%

2%

Plastics approx. 15-18 %

Use of material in modern cars

Total 1,429 kg

Steel

Others

Plastics

Aluminum

Glass

Source: Polymotive

Elastomers

Fluids

Cast Iron

Str

en

gth

Stiffness

unreinforced

30 % GF

AKV 50 (dry)

BKV 50 (cond)

DP BKV 60 EF (cond)

AKV 50 (cond.)

BKV 50 (dry)

DP BKV 60 EF (dry)

T 7391 DP T 3150 XF

high modulus grades

Durethan

high modulus grades

Pocan

Characteristics - mechanical properties

high strength

high modulus

[%]

PA 6 GF30 PA 6 GF30 easy flow

0

50

100

150

200

250 Flow Length

Flexural Modulus

Izod 1U

Filling Pressure 3

26

ba

r

43

cm

83

00

MP

a

60

kJ

/m2

44

%

18

1 %

89

%

10

8 %

10

0 %

21

0 %

PA 6 GF60 easy flow

10

0 %

13

5 %

PA6 GF60 with good flowability: Durethan® DP BKV60 H2.0 EasyFlow EF

0

5000

10000

15000

20000

25000

23 80 120 170

Ela

sticity m

od

ulu

s, M

Pa

High e-modulus at elevated temperatures based on the example of PA6

• High service

temperatures of

170° C and

above

• High heat

conduction (60 %

GF) and faster

demolding due to

high stiffness

result in shorter

cycle times.

Temperature, °C

Durethan® BKV 60 EF (PA 6 GF 60)

Durethan® BKV 30 (PA 6 GF 30)

Low warpage, high dimensional stability

0

0,2

0,4

0,6

0,8

1

Molding shrinkage Post-shrinkage

0,55 %

0,34 %

Lower shrinkage

difference

lower warpage

PA 6 GF 30 PA 6 GF 60 EF

Sh

rin

ka

ge

, %

0

0,5

1

1,5

2

2,5

Wa

ter

ab

so

rpti

on

, %

23 °C, 50 % r. F.

Lower water

absorption high

dimensional

stability

PA 6 GF 30 PA 6 GF 60 EF

Solution to Warpage: Durethan® DP BKV 60 EF H2.0:

Actual Z-direction deflection ~ 3.4 mm

PA66GF35

Actual Z-direction deflection ~ 1.2 mm

DP BKV60 EF

Problem: Warpage and leakage after key life test in PA66 GF35.

Calculated Z-direction

deflection ~ 3.8 mm

(Scale Factor = 5)

(Scale Factor = 5)

-65%

Case study: automotive cylinder head cover Durethan® DP BKV60 H2.0 EasyFlow vs. PA66 GF35

Creep performance of Durethan® DP BKV60 H2.0 EF

2 Years

Ago Today

What is “Creep”?

0.0

0.5

1.0

1.5

2.0

2.5

3.0

0.000 0.001 0.010 0.100 1.000 10.000Time [h]

Elo

ng

ati

on

[%

]

PA66 GF35

PA6 GF35

DP BKV60 EF (PA6 GF60)

Time-elongation curves at 170°C / 30 MPa

After 10,000 hours at 170°C/30 MPa, Durethan DP BKV60 EF shows 40% less creeping

than PA66 GF35

Better dimensional stability, even at elevated temperature

Creep performance of Durethan® DP BKV60 H2.0 EF

Constant Force

Durethan® BKV60 H2.0 EF

Application example: door handle

Good paintability

Excellent dimensional accuracy

Fast cycle time

Substitution of amorphous PA GF40

OEM: Daimler, Porsche, Jaguar

Application example: air vent lamellas

OEM: several (e.g. Volvo)


Good stiffness and strength

Good surface quality


Application example: hight adjustment lever steering wheel

OEM: Opel (Insignia)




Application example: tailgate handle

OEM: Audi


Good surface quality


Part weight: 9 kg

Shot weight: 12 kg

Dimensions: 100 x 85 x 32 cm

Application example: spare wheel pan

OEM: Audi (A8)


Cost and weight reduction vs. former

SMC or metal design

High stiffness and strength to carry 70 kg

of assemblies like compressor for the

suspension system, AdBlue tank, battery,

spare wheel, tools, etc. Glued into BIW,

contributes to the stiffness

Cost reduction vs. former

metal design

Low creep behaviour

High stiffness

permanent load by spring

Application example: furniture hinge


Cost and weight reduction

vs. former metal design

High stiffness

High heat resistance

High dimensional accuracy

two halves must fit together

Application example: gear drive housing of vacuum cleaner


High stiffness

Low warpage

Easy processing

Axles must be parallel

Application example: meat mincer frame


BKV60: 354g Aluminum: 536g

Cost and weight saving vs.

former cast aluminum design

Very high stiffness

High dynamic load capacity

Application example: luggage carrier


Safety is critical issue:

- Load test: 50 kg vertical dynamic

loading

- Road test: 20 km running test with

30 kg loading, at a speed of 1.4 m/s

on a treadmill style testing device with

artificial bumps mounted onto the belt.

Application example: baby stroller

Durethan® BKV60 H2.0 EF (& BKV30, B30S)

Application example: structural parts of stadium seats (Wembley, Soccer City in South Africa,..)

Durethan® BKV60 H2.0 EF (& BKV30, B30S)

Application example: power tool components


Gearbox housing

Gears

Bearing bushes

Cost and weight saving vs. cast Al and

PA66+GF50

Excellent dimensional stability –

low noise

Good dynamical load bearing

capacity

Positioning of high filled PA6, 66 and PBT amongst other high-performance polymers

PA 66 GF 50

PA 6 GF 50

PA 6 GF 60 EF

PBT GF 45

PBT GF 60

LCP GF30

PPS GF30

PPS GF+Min 65

PEI GF 45

PSU GF30

PA4.6 GF60

PA12 GF50

LCP GF 50

PA 66 GF 50

PA 6 GF 50

PA 6 GF 60 EF

PBT GF 60

PPS GF30

PPS GF+Min 65

PEI GF 45

PA4.6 GF60

PA12 GF50

LCP GF 50

50

100

150

200

250

5000 10000 15000 20000 25000

E Modulus [MPa]

Str

es

s a

t B

rea

k [

MP

a]

PSU GF 30

LCP GF30

PBT GF 45

E-Modulus

resistance against heat deflection

stress at break, strain at break

colour, painting

surface quality

costs of processing and assembly

reworking

freedom of design,

component integration

density

die cast metal

high modulus

material

Positioning of high filled PA6, 66 and PBT against die cast metals

Table of Contents







1. Engine Trends



Lanxess Hybrid Technology Introduction to market in 1997

Applied to more than 40 Mio. cars

Weight reduction up to 30% versus full metal

LANXESS hybrid technology

Lightweight structures

(thin wall thickness)

preference for denting

or buckling

The structure can be

supported with small

forces, that are carried by

the plastic ribs

F1 F2

→ →

Fplastic Fplastic

→ →

F2 >> F1

→ →

sheet metal

support

Thin walled metal structures under load can be held in shape by low forces.

Working principle of hybrid technology

Open mold Demold finished part Position

sheet metal insert

Combination of metal stamping and injection molding

Manufacturing of hybrid technology

over-molded

edge sheet metal profile

molded „button“

plastic rib structure molded „button“

over-molded

edge

Design features of hybrid technology

Cross section of hybrid structural beam

Fo

rce

F

[k

N]

4,0

3,0

2,5

2,0

3,5

1,5

0,5

0

Deflection f [mm] 8 0 2 4 6 10 12 14 16 18 20

5 0

Metal/plastic Hybrid profile

Closed metal profile

Open metal profile

3 4 0

f

F

40

Component properties

3-point bending test

Fo

rce

F

[k

N]

25

20

15

10

5

0

Deflection f [mm]

2,4 0 0,8 1,6 3,2 4 4,8

340

5 0

40



Open metal profile


Compression test (energy absorption)

Mo

me

nt M

[N

m]

40

25

20

15

30

10

5

0

Rotation Angle j [] 8 0 2 4 6 10 12 14 16

340

35

5 0

40



Open metal profile


Torsional test

Over 70 applications running in mass production,

over 40 Mio. hybrid parts manufactured.

Ford Galaxy – 2006 Ford S-Max – 2006 Audi TT – 2006 Hyundai Avant– 2006 Hyundai Veracruz– 2006 Hyundai Santa Fe – 2006 Kia Carens – 2006 Kia Lotze – 2006

…and a lot

more!

Ford Mondeo – 2007 Audi A5 - 2007 Audi A4 - 2007 Hyundai i30 – 2007 Hyundai Starex– 2007 Audi Q5 – 2008 Ford Kuga – 2008 Hyundai Genesis - 08

Audi Q7 V12 – 2008 Audi A3 – 2008 Audi A7 – 2010 Audi A1 – 2010 Audi A8 – 2010 new Focus 2010 new A/B-class 2011

Audi A6 – 1998 Audi A4 – 2000 Ford Focus – 1998 Ford Fiesta – 2001 Renault Megane – 2002 Mazda Demio – 2002 Hyundai Getz – 2002 Kia Spectra – 2003

Mercedes Benz A – 2004 Chrysler 300C – 2004 VW Polo – 2001 Nissan Quest – 2003 BMW X3 – 2003 BMW 1er – 2004 BMW 3er – 2005 Mercedes Benz Vito – 2003

Application example: hybrid frontend structure

http://images.google.de/imgres?imgurl=http://www.oracle.com/technology/products/bi/olap/olapref/ford_logo.gif&imgrefurl=http://www.oracle.com/technology/products/bi/olap/olap_references.html&usg=__c1KEQlhOI6gTlLt4joTgM-cAsdk=&h=422&w=838&sz=62&hl=de&start=7&tbnid=rTaNH3S-zJeZAM:&tbnh=73&tbnw=144&prev=/images%3Fq%3Dford%2Blogo%26gbv%3D2%26hl%3Dde

http://images.google.de/imgres?imgurl=http://www.vikingautoparts.com/mercedes/images/mercedes_logo.jpg&imgrefurl=http://www.vikingautoparts.com/mercedes/mercedes.html&usg=__ki09UtHI02hdTlYLA-MzP7AUtto=&h=320&w=336&sz=7&hl=de&start=3&tbnid=DOYmD7uI2MZIpM:&tbnh=113&tbnw=119&prev=/images%3Fq%3Dmercedes%2Blogo%26gbv%3D2%26hl%3Dde

Application example: hybrid frontend module carrier Audi A2

Functional integration of frontend module carrier of Audi A2

Fiat Ducato

Mercedes C-Class

Durethan® BKV30 H2.0

Application example: hybrid brake pedal & pedal box

Durethan® BKV30 and BKV130

1 deep-drawn

sheet metal

Overmolded plastic

(PA6 30% GF)

Application example: office chair base concept

Table of Contents







1. Engine Trends



Substitution of sheet metal by plastic composite sheet

Preformed Plastic Composite

Sheet with 50% PA6 and

50% Glass Fiber rovings

Next generation Hybrid

Technology test specimen

with Plastic Composite Sheet

and Durethan

Next generation hybrid technology: composite sheet hybrid

Manufacturing of composite sheet hybrid

The diagram compares the angel of

rotation-torque curve of a hybrid

part with composite sheet (346 g,

2 mm) and a steel sheet (400 g,

0.7 mm). It shows the excellent

material properies of overmolded

composite sheets at the torsional

test:

~ 50% higher stiffness

~ 65% higher strength and

significant higher energy

absorption

Torque-angel-curve of a torsional test.

0

0,1

0,2

0,3

0,4

0,5

0,6

0 10 20 30 40 50 60 70 80 90

angel of rotation / [°]

we

igh

t re

late

d to

rqu

e / [

Nm

/g]

composite sheet

steel

Torsional test of composite hybrid beam

we

igh

t re

late

d fo

rce / [

N/g

]

The force-deflection-curve of a

hybrid part with composite sheet

(346 g, 2 mm) in comparison to a

steel sheet (400 g, 0.7 mm) at a

bending test shows the excellent

material properties of overmolded

composite sheets:

With a slightly lower stiffness the

composite sheets convince through

- double strength and

- double energy absorption

0

2

4

6

8

10

12

14

16

18

20

22

24

26

0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 deflection / [mm]

Force-deflection-curve of a 3-point bending test

composite sheet

steel

Bending test of composite hybrid beam

Bill of materials: Durethan BKV30 H2.0 EF PA+GF composite sheet Aluminum

Aluminium insert

Composite sheet

Application example: new frontend carrier Audi A8

Application example: new frontend carrier Audi A8

• Excellent design freedom, no rework after

molding

• Low weight, heigh strength and stiffness

• High energy absorption (crash)

• Part cost reduction vs. welded steel structures

• Lower investment costs compared to full steel

solutions

• Good dimensional accuracy & stability

• Mass production approved manufacturing

processes, one-shopt-process possible with

composite sheets

• No corrosion with composite sheets

• Easy to recycle (only one material)

• For large scale production (sheet metal) and

small scale production (composite sheet)

Advantages Considerations

Summary hybrid technology

• Number of parts (small-volume advantage

with composite sheet)

• Metal-hybrid requires higher investment

costs compared to full plastics solution, but

similar investment with composite sheet

• Influence of temperature and humidity

• Simulation tools for composite sheet hybrid

under development

Fiber types and processing technologies for structural parts

Table of Contents







1. Engine Trends



Reduction of Emissions and consumption

Higher rate of exhausted gas return (EGR)

Weight reduction

Smaller charged engines (diesel and petrol)

Smaller package space due to charged engines and CW- triggered design

Increased temperature and pressure for air duct systems

New emission targets for tanks

Higher & new requirements on plastic materials

Car engine development – reduction of emissions and consumption

0

10

20

30

40

50

60

70

80

2008 2010 2012 2014 2016 2018 2020

%

Diesel Gasoline downsize/turbo Stop/start

• Currently engine downsizing / charging is the

most significant change in engine design.

• Hybrid electric vehicles and battery electric

vehicles will increasingly become important,

driven by stricter CO2 regulations, rising oil

price and ecological awareness of consumers.

Source: JD Power

Western Europe forecast

Trend engine downsizing

Instead of traditional AIM

small “intake cover”

Charged air system

Engine oil pan

Plastics in modern turbo charged engine

C:/Documents and Settings/chthb/My Documents/Automotive/Index-engl.ppt

Air filter

Turbo charger

Clean air duct

Charged air cooler Resonator

“Hot side”

“Cold side”

BMW Mini: clean air and charged air system

≤ 100°C

80 – 150°C

130 – 220°C

80 – 160°C

A

B

C

D

Temperature Air pipes

intercooler

AIM

Exhaust

gas

air

Air filter

Turbo Charger

A: ≤

100°C

B: 80-150°C C: 130-220°C

D: 80-160°C

Engine clean air and charged air system temperatures

Application examples: air ducts in LANXESS Durethan®

Conventional blowmolding

Source: Fischer W. Müller Blasformtechnik Source: Krupp-Kautex Maschinenbau

Conventional blowmolding: up to 80 % material scrap

Solution: 3D blowmolding

3 D blowmolding technologies

Suction blowmolding

Parison handling

Source: SIG Kautex, Bonn

Kkv55_1.mpg

Table of Contents







1. Engine Trends



Polyamide melt strength

0

20

40

60

80

100

120

140

160

0 20 40 60 80 100

Theoretical Lenght [cm]

Eff

ecti

ve L

en

gh

t [c

m]

Linear Standard-PA6 Durethan B40 E

Durethan® BKV315 Z

10 15

20

25

30 sec

Durethan® blow molding product portfolio for hard and super-soft ducts

230

980

350

1300

750

2700

2500

5400

4000

7400

3500

6300

5300

8500

0

1000

2000

3000

4000

5000

6000

7000

8000

Te

ns

ile

Mo

du

lus

[M

Pa

]

BC 700

HTS

DP BC 600

HTS

DP BC 500 BKV 315 Z TP 140-

008

DP

2240/15

AKV 325

ISO 1110 d.a.m

Regulations - Reduction of Emission and Permeation

EPA 40 CFR (USA 2010)

Exhaust emission limit value HC+NOx 0,8g/km and CO 12g/km (since 2010)

(exhaust gas components: hydrocarbon, nitrogen oxide, carbon monoxide)

Permeation <1.5g/m²/day (tanks)

- Preconditioning (20 weeks)

- Baseline permeation test (2-4 weeks)

- Pressure cycling (10000x0.5-2psi) / UV Exposure (24W/m² - 15h/d for 30days) / Slosh testing (shaker 1 million cycles)

- Fuel soak (similar to preconditioning)

- Final permeation test (like Baseline test)

New emission requirements on fuel and lubricant tanks of small engines USA: EPA

EPA compliance – who is affected?


97/24/EG ECE Accreditation (Economic Commission for Europe - 1997)

- Permeation test (similar to EPA, but 20g/24h)

- Impact test (tank at -30°C)

- Pressure test (0.3bar for 5h)

- Fire test (0.64mm/sec)

- Temperature testing (Tank 1h at 70°C – deformation, Leakage)

New emission requirements on fuel and lubricant tanks of small engines Europe


SAE J1241 (Society of Automotive Engineers ) „guideline“ (1999)

- Leakage test at low temperature (-20°C)

- Leakage test at high temperature (60°C)

- Internal pressure test (150% of pressure relief set point or at least 0,35bar)

- Pressure relief test (150% or 0,35bar)

- Cap leakage test (filled rotating tank)

- Outdoor exposure test (1year, angel 45°, Arizona desert or equivalent)

- Impact test (aged tanks at -20°C and 60°C)

- Longitudinal deceleration test (simulation of frontal impacts)

- Lateral impact (pendulum)

New emission „guideline“ on fuel and lubricant tanks of small engines USA: SAE

Choice of material

- HDPE? – permeable against fuel !

Fluorination (barrier film) latest requirements not achieved / long-life problem ?

Blend with PA latest requirements not achieved / impact strength not sufficient

Multilayer expensive, recycling not easy

6-Layer KKB Krupp Kautex with EVOH (Ethylen Vinyl Alcohol)

HD

PE

HD

PE

HD

PE

- R

eg

en

era

te EVOH

Adhesion Mediators

5 mm

38% 43% 12% 3% 2% 2%

Future material selection for fuel and lubricant tanks of small engines

E.g. car tank fuel layer system:

Rotation process (PA and PE)

Brittle behaviour

Long cycle times

Monolayer solution with Durethan Blowmoulding

e.g. Durethan® TP142-011 =

0.1g/m²/d (requirement EPA 1.5g/m²/d)

Durethan® blow molding grade for fuel and lubricant tanks of small engines

Durethan® TP142-011 = 0,1g/m²/d

Currently running since 18.01.2011 until 29.3.2011

Final permeation test - Takes 2 weeks – final result expected 19.4.2011

After this test additional dimension test

Durethan® blow molding grade for fuel and lubricant tanks of small engines

Table of Contents







1. Engine Trends



CAE integrative simulation

Surface layer:

random orientation

Shear layer:

ll to flow direction

Core layer:

to flow direction

(fountain flow)

Orientation due to flow processes Result: Anisotropic layer structure

V

V

The fibre orientation is different over the part and in thickness direction !

Fibre orientation in injection moulded parts

0

200

400

600

800

1000

1200

1400

1600

1800

0 0.5 1 1.5 2

Displacement (at clamp) [mm]

Fo

rce

[N

]

Parallel to flow Perpendicular to flow

Dependence of material properties on fibre orientation

• Durethan BKV35 (1 % cond.)

• EMI-Specimen: t = 2 mm

• T = 23 °C / v = 0.35 mm/min

There is no global

and universally valid

scaling factor for the

determination of

isotropic properties !

0.5 1.5

Tensile test parallel and perpendicular to fibre orientation

Linking process simulation and structural analysis

Process simulation

Fibre orientation Shrinkage

Local directions

Stiffness

Thermal expansion Stresses/Warpage

Strength

Structural analysis

Integrative

Simulation

Example: oil pan thermal expansion 23°C=>75°C.

0

10

20

30

40

50

60

70

6 - 8 5 - 9 4 - 10 1 - 3 1 - 8 2 - 7 3 - 6

Measuring points

CT

E [1

E-6

]

Measurement Anisotropic 2,5D Isotropic 2,5D

Integrative Simulation

Boundary conditions: Fixation

Design space: Within this

space (volume) material

can be placed or displaced

Load F

Load F

• After the automatic iterative optimization process, material

is placed in areas contributing to the part„s stiffness

„Mathematical Bridge“

Cambridge, GB

Topology optimization

Best possible structural design

Prototype

Initial sheet design

Customer requirements

Preliminary design

Too heavy

Producability

Over-engineered

Steel: 506g

Plastic: 302g

Optimized PMH

design fulfilling

specs

Steel: 506g

Plastic: 202g

Optimisation

• Stiffness

• Moldability

• 100 g weight

saving

Topology optimization

Summary

• The amount of polymers (and Polyamide in particular) in automotive will continue to rise due to

the increasing demand for lightweight structures.

• High modulus thermoplastics are required for further metal substitutions.

• Composite sheets are a promising solution for high performance structural components not only

in automotive. First mass-produced applications have been launched.

• More efficient engine concepts lead to demand for plastics in new and growing applications,

especially in the area of blow molded articles (and in the electrification of cars).

• Upcoming regulations for small engine fuel and lubrication tanks require a change to different

materials.

• New CAE methods will also in future help to reduce development times and costs and will allow

to further advance design concepts.

Thank you for your attention.

Thomas Babl

Phone: +852 3526 8844

[email protected]

mailto:[email protected]