Metals such as steel and aluminium are likely the first things that might come to your mind when considering the materials utilised in producing automotive components. However, the automotive industry has increasingly used plastics in manufacturing in recent years.
In this article, we will examine the multiple applications of plastic in the automobile manufacturing business and the causes that have contributed to the spectacular rise of this material’s usage in the automotive industry.
To assist you in gaining a more thorough understanding of the importance of plastics, the article’s primary focus will be on the material’s specific characteristics and its many applications in automobile component manufacturing.
As you continue to read this article, you will learn about the unique applications of plastic in automobiles and the factors that contribute to the huge dependence of the automotive industry on plastics.
When investigating its qualities and countless benefits, you will learn how this flexible material enhances automobiles’ functioning, aesthetics, and user experience.
You will be amazed by the fact that something as simple as plastic has managed to revolutionise the automotive industry.
Why Use Plastic in the Automotive Industry?
Improved Safety:
Plastics are crucial for improving automotive safety measures. For instance, plastics are used to make seat belts, airbags, and kid safety seats, critical for safeguarding passengers in an accident.
The energy absorption, impact resistance, and cushioning characteristics of plastic materials serve to lessen the impacts of impacts and the possibility of injury.
Design Flexibility:
The versatility of plastics in design extends to molding and shaping complicated curved and molded shapes. Increased creative flexibility for the vehicle’s designers can result in improvements in both its aesthetics and its performance.
Attractive interior panels, appealing exterior trimmings, and comfy seating are examples of how plastic components may be molded into various forms to satisfy multiple objectives and aesthetic preferences.
Minimal Corrosion Damage:
The corrosion resistance of plastics makes them an excellent material for use in automobiles. Plastics are resistant to all corrosive substances, unlike metals, which may corrode gradually due to contact with water, chemicals, and road salt.
Exterior trim, Fuel tanks, and underbody panels are just some places where corrosion damage can be prevented or delayed through corrosion-resistant polymers.
Durability and Longevity:
Automobile plastics are designed to be durable and reliable under extreme conditions. They resist problems like rust, dampness, chemicals, and UV rays.
Your automobile will survive longer since plastic parts won’t degrade as quickly as metal ones, and these parts are more durable than any other material.
Vibration, Noise, and Damping:
Plastics can decrease road noise and vehicle vibrations, leading to a more relaxing and enjoyable driving experience. Using plastics with sound-dampening characteristics in vehicle interiors may significantly improve passenger comfort by reducing annoying engine and road noise.
Plastics can also absorb vibrations, enhancing ride comfort and decreasing passenger fatigue on long drives.
Weight Reduction:
In several applications, vehicle weight could be decreased using plastics instead of metals. The lighter load means your car uses less petrol and produces fewer greenhouse emissions over its lifetime.
Better handling, acceleration, and braking performance could be attained with more delicate parts, leading to a pleasant driving experience.
Environmental Sustainability:
The usage of plastics in the automobile sector is consistent with attempts to achieve environmental sustainability. Plastics assist in reducing excess weight, which in turn improves fuel efficiency and decreases pollution.
In addition, many plastics used in modern automobiles are recyclable, facilitating waste reduction and resource preservation. Recycling programs assist in preventing plastic waste from ending up in landfills, promote a circular economy, and lower the automobile industry’s environmental effects.
Weight Saving:
Plastics provide substantial weight savings in vehicle parts due to low density. The vehicle’s energy efficiency has increased due to the weight reduction.
Lightweight polymers may be used in many places, including interior trim, body panels, and engine components, resulting in considerable weight savings that reduce fuel usage and lower emissions.
Most Commonly Used Plastics in Automotive and Their Applications
Polypropylene (PP)
Polypropylene (PP) is widely used in the automobile sector because of its adaptability, durability, and other outstanding characteristics.
Dashboard:
PP is often used to manufacture dashboards due to its excellent temperature, impact and UV resistance. Because of its low weight, it uses less fuel while travelling the same distance.
The dashboard is a highly trafficked vehicle area, and PP provides these benefits by being dimensionally stable, durable, and scratch and wear resistant.
Door Panels:
PP door panels provide durability and cost efficiency by balancing weight and strength. PP’s impact resistance and stiffness make these panels an appropriate material option since they are often opened and closed and susceptible to passenger impacts.
Center Console:
Center consoles, which include buttons and storage bins, are often made of PP. PP is perfect since it can withstand much wear without breaking or being stained.
PP is versatile because it can be formed into intricate shapes, opening the door to new forms and possibilities in design and functioning.
Bumpers:
Bumpers are often made out of PP because of the material’s high resilience to impact and high energy absorption.
PP bumpers serve to protect the vehicle’s structure and passengers from injury in the case of a crash. The reduced vehicle weight and increased fuel economy are advantages of using PP.
Polyurethane (PUR)
Because of its remarkable mechanical properties, durability and flexibility, polyurethane (PUR) is a flexible material often used in the automobile industry.
Seats:
PUR foam is widely used in car seats as a comfort, cushioning, and support material. It performs well over a long period and has excellent elasticity and cracking resistance.
The whole driving experience is improved by PUR foam since it can be customizcustomisedh particular support and comfort demands.
Armrests:
PUR’s flexible and soft nature makes it a popular material for making armrests since they provide riders with a pleasant riding experience. PUR armrests have the added benefit of reducing fatigue and vibration during long journeys.
Headrests:
PUR foam headrests provide better resistance to impact and adsorption of shock, increasing safety during accidents. They reduce the possibility of spine and head injuries while giving the passengers comfort and support.
Polyvinyl Chloride (PVC or Vinyl)
PVC’s adaptability, durability, and low price make it an ideal material for the automotive sector.
Wire Insulation:
PVC has excellent electrical characteristics, heat and flame resistance; hence it is often used as insulation in vehicle wiring. It prevents the electrical wires from being damaged by water, wear, and electrical shorts.
Flooring:
PVC flooring is long-lasting, simple to clean, and resistant to damage. It’s a common choice for heavy vehicles used for commercial and other industrial purposes since it’s durable and easy to clean.
The flooring made of PVC also insulates sounds and enhances the comfort of passengers.
Upholstery:
Because of its durability, ease of washing, and resistanceageingging, PVC upholstery is often used for the seating surfaces found in motor vehicles.
It provides a wide variety of design possibilities, which enables car manufacturers to construct aesthetically pleasing interiors.
Acrylonitrile Butadiene Styrene (ABS)
Acrylonitrile butadiene styrene (ABS) is a thermoplastic polymer with extensive engineering use. Because of its endurance and resistance to impact, it has become a well-known type of plastic material.
Instrument Panels:
ABS instrument panels can withstand temperature, impact, and physical change fluctuations without damage. They may be formed into intricate designs, making it simple to include features like buttons, vents, and screens.
Grilles:
ABS grilles provide several advantages, including increased durability, resistance to impact, and more design freedom.
Polyamide (PA/ Nylon 6/6, Nylon 6)
Polyamide is a lighter material with higher stiffness and frictional coefficient that makes it a suitable material for Automotive Industry.
Engine Covers:
The greater chemical resistance of polyamides makes them able to protect the surface of product with affecting pollutants. Due to a strong barrier, the chemical cannot be even stay on the surface, protecting the engine greatly. Greater thermal stability also an advantage of these materials.
Fasteners:
PA fasteners are often utilised during assembly to ensure the safety and durability of the vehicle’s parts. The shockability of polyamides with sustainable durability is key property of polyamides.
Polystyrene (PS)
Due to its low cost, simple production, and superior insulating characteristics, polystyrene (PS) is often utilised in automobile components.
Dashboard Trims:
PS-based dashboard trims are simple to manufacture and install while delivering an aesthetically pleasing finish.
They provide versatility in design since they can be molded into many different forms and structures. PS trims help reduce overall car weight since they are lightweight.
Door Trims:
PS door trims have a lighter structure, are economical, and are versatile in design. They make for a fine final touch inside; you can even build in accessories like speaker grilles. PS door trims also help to quiet down the inside of the car.
Polyethene (PE)
Polyethene is frequently used in automobiles because of its low cost of manufacture, excellent resistance to chemical degradation, and easy manufacturing process.
Seat Belts:
Polyethylene (PE) is a material often used to manufacture seat belts. This is primarily due to the material’s exceptional abrasion resistance and high tensile strength.
High bearing ability and consistency of Polyethylene (PE) based seat belts make allow to ensure the protection of passengers in any unwanted or unfortunate incident.
Fuel Tanks:
The aerodynamic characteristics of PE are considerably better than other materials specially weight leading to less power consumption. The other dominant properties are chemical resistance, impact resistance and durability.
Impact resistance is very important as it safe the passengers in any unfortunate condition followed by a hit or impact.
Polyoxymethylene (POM)
Polyoxymethylene (POM) due to its high structural strength and dimensional stabilized nature, is used in automobile industry. The have greater durability and ductility because of their greater thermal stability.
Steering System Components:
POM is generally utilized for the manufacturing of small parts and accessories being used to align the steering systems of motor vehicles due to higher strength and anti-fatigue nature.
Because of above mentioned properties of POM it is highly considered for production of steering systems in vehicle industries.
Air Vent Controls:
Air Vent systems always require the properties of resistance to chemicals, easy assembly and thermal stability. The high precision POM products are excellent option for air vent systems considering automobile consumer’s comfort.
Polycarbonate (PC)
Polycarbonate, commonly referred to as PC, is a material with exceptional optical properties and hardness that is frequently used in the manufacture of automotive parts.
Headlight Lenses:
PC headlights contain very clear lenses, strong and resistant to the harmful effects of ultraviolet light. Their dependable and durable lighting may boost the safety drivers, and pedestrians feel on the road.
Sunroofs:
Due to the PC’s high degree of transparency, resilience to impacts, and UV radiation resistance, the material is employed throughout the construction of sunroofs. PC sunroofs increase driving comfort by allowing pleasant natural light into the car.
Acrylic (PMMA)
Polymethyl Methacrylate (PMMA) or acrylic is a clear plastic widely utilised in the automobile industry due to its high clarity, durability, and aesthetic flexibility.
Taillight Lenses:
Taillight lenses made of polymethyl methacrylate (PMMA) provide superior clarity, durability, and weather-resistant properties. With their bright and long-lasting illumination options, you can see clearly and be seen by other drivers at all times.
Light Covers:
Protecting automobile lights with PMMA covers is possible since the material is transparent. They won’t turn yellow or fade with time, so you can depend on them for a long time of use with attractive looks.
Interior Lighting:
PMMA’s optical characteristics and diffuse light make it ideal for use in the creation of indoor lighting lenses and fixtures. Using PMMA lighting solutions, you may make your home more welcoming and aesthetically pleasing.
Polybutylene Terephthalate (PBT)
Thermoplastic Polybutylene Terephthalate (PBT) is widely utilised in the automobile sector because of its high mechanical strength, low ductility, and high resistance to extreme temperatures and harsh chemicals.
Connectors and Terminals:
With a high degree of dimensional stability, heat, and chemical resistance, and low electrical conductivity, PBT connectors and terminals provide sturdy electrical connections. They provide safe and effective electrical transmission in several automobile systems.
Polyethylene Terephthalate (PET)
PET, a strong and lightweight plastic with outstanding mechanical characteristics, transparency, impact resistance, and chemical resistance, is employed in the automobile sector.
Carpet Fibers:
PET fibres are employed to make vehicle carpets because they are enduring, stain-resistant, and simple to maintain. PET carpet fibres provide an attractive and aesthetically pleasing interior flooring option, boosting the car’s overall attractiveness and comfort.
Acrylonitrile Styrene Acrylate (ASA)
The automobile industry relies on weather-resistant thermoplastic acrylonitrile styrene acrylate (ASA) because of its impact strength, high resistance to ultraviolet light (UV), and color retention (colours don’t fade).
Roof Panels:
ASA roof panels resist color stability, weather, and impact. They keep the vehicle’s interior and passengers safe from extreme weather. The ASA roof panels help keep the vehicle’s interior insulated from heat and noise.
Exterior Trims:
Moldings and spoilers made with ASA material are attractive, long-lasting, and resistant to weathering and fading. They serve a dual purpose of enhancing the vehicle’s aesthetic and safeguarding its underpinnings.
Selecting the Best Plastic Material is Critical to Making Perfect Car Parts
Many different types and grades of plastic are available, making it difficult to choose the best one for the automobile’s components. Don’t worry; You do not need to go through this procedure alone, as Kemal Plastic Injection Molding Services is here to help you in the best possible way.
The current automobile sector has particular requirements that must be met, and the experienced team members at Kemal are familiar with these requirements.
We will help you identify which polymers will best fulfil your needs since we have the necessary expertise and resources. It is possible to increase the performance, durability, and safety of the components of your vehicle by giving careful consideration to the material selection.
When working with us, we will handle all your material-related requirements. When choosing materials for your automotive components, we consider all factors, including toughness, reliability, durability against impacts, heat resistance, dimension stability, and chemical resistance.
You will also get help streamlining and improving plastic product production.
Our experience with a wide variety of plastics enables us to give valuable insight into the advantages and disadvantages of each plastic material.
We’ll guide you through selecting which polymers are appropriate for your vehicle components based on cost, ease of production, endurance, and ecological impact.
We at Kemal will also assist you with the appropriate polymer formulations for your custom requirements. Moreover, our lab has the equipment to undertake thermal analysis, mechanical testing, and chemical resistance testing to ensure the material is safe for automobile use.
Feel free to contact us with any inquiries. We will be happy to assist in developing safe, high-quality automotive components.
