Covestro is the largest supplier of polycarbonate worldwide, addressing pressing challenges and developing high-tech solutions used in many areas of daily life. We serve a range of applications in the automotive industry including interior & exterior elements, lighting, seating, ePowertrain and electric vehicle battery (EVB) packaging, using dedicated raw materials for coatings and adhesives, thermoplastics, foams, films, composites and more.
From bumper to bumper:
Covestro materials for future-forward automotive concepts.
As the automotive industry continues to evolve, we are rethinking the design and functionality of vehicle components.
Electric vehicles (EVs) are creating new design possibilities for front grilles, such as the transformation from open grilles to closed grilles and the integration of signature light, 3D patterns and color effects using transparent and impact-resistant polycarbonate.
Dynamic light and display integration come together in our front grille demo: a seamless polycarbonate grille with a metallized 3D rear structure and rear projection technology. A second prototype utilizes Makrolon® AG2677 ST polycarbonate for seamless LiDAR integration into exterior parts with silver printed LiDAR black Makrofol® film. To incorporate functionalized films into the design, we developed 5D film insert molding (FIM) technology, which combines rear 3D structures with color and decoration.
Emerging automotive technologies also create a demand for new ways to incorporate styling and connectivity into traditional body components. We delivered the ultimate combination of look and function with our next-generation roof spoiler concept, which integrates sensors, cameras and lighting elements for enhanced safety and unlimited design opportunities. Polycarbonate materials provided an excellent material for these components.
For example, Makrolon® polycarbonate offers excellent transmission properties for 5G signals while enabling seamless design and integration of 5G modules. Additionally, our DirectCoating technology allows OEMs to create stylish and functional surfaces with an efficient two-stage manufacturing process that combines conventional thermoplastic injection molding with an in-mold coating. The result: a polyurethane-coated high-gloss spoiler with outstanding properties.
Polycarbonate materials enable good signal reception and transmission for integrated sensors, cameras and antennas. This is particularly important for autonomous vehicles that need these components to help them navigate safely. The Makrolon® polycarbonate material featured has excellent transmission properties for 5G signals. It also enables seamless design and integration of 5G modules.
The automotive lighting evolution will call for smaller and sleeker shapes, new thermal management strategies, reduced system costs, integration of advanced driver-assistance systems, and enhanced branding and aesthetics for automakers. We are supporting these future challenges with a lighting demonstrator that showcases several forward-looking lighting components and supportive technologies.
Polycarbonate lights the way in the demonstrator, with properties to meet the optical purity, heat performance, durability and processing needs for lighting applications. Makrolon® TC 8030, DS 801 and LED 2245 polycarbonate grades are used for the lighting components. These materials, together with innovative designs, optimized processes and consolidated parts, create a lower-cost system. The demonstrator also displays different light diffusion, transmission and color options.
Lighter materials combined with design freedom:
- Polycarbonate materials reduce weight while enabling greater design freedom in front grilles.
- Increased connectivity: In roof spoilers, polycarbonates enable good signal reception and transmission for integrated sensors, cameras and antennas.
- High durability: Polycarbonate materials provide dimensional stability and durability over a wide temperature range.