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Leveraging plastics and composites for a sustainable automotive future
Leveraging plastics and composites for a sustainable automotive future

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In the last decade, the automotive industry has witnessed a remarkable shift towards using plastics and composites. This transformative journey has been revolutionary, as we’ve observed an ever-increasing reliance on these materials in vehicle manufacturing. This shift’s implications are far-reaching and set to redefine the future of the automotive landscape. Global Electric Vehicle Plastics market is expected to grow from $3.7 billion in 2022 and is projected to reach $12.6 billion in 2027, at a CAGR of 27.9% during the forecast period.

Application & challenges of plastics and composites in automotive

The data paints a compelling picture. The use of plastics in automotive applications is on the rise, with predictions suggesting that by 2030, there could be up to 17% more plastic used per vehicle. Today, plastics account for up to 50% of a vehicle’s volume, indicating a substantial shift away from traditional metal components.

This transformative journey not only tackles challenges in e-mobility adoption but also shapes a future where these materials redefine automotive efficiency, safety, and sustainability. Embracing the shift toward electric mobility, the automotive industry encounters several challenges, each met with innovative solutions through the application of plastics and composites.

Weight constraints – It is a crucial concern for electric vehicles (EVs), which are effectively addressed as these materials offer a substantial reduction compared to traditional metals, enhancing overall efficiency and extending the range of EVs. For electric vehicles, a 10% weight reduction typically equals a 13.7% increase in range.

Battery Weight and Range Anxiety – The weight of batteries, a major contributor to range anxiety, is mitigated by incorporating plastics and composites in battery enclosures.

Safety Standards and Flame Retardancy – Safety standards, particularly flame retardancy, are diligently met through the inherent properties of these materials, reducing the risk of thermal incidents in EVs.

Electrical Components and Heat Management – The need for efficient heat management in electrical components finds a solution in the superior thermal insulation properties of plastics and composites, ensuring optimal performance.

Environmental Sustainability and Recycling – As environmental consciousness grows, the industry grapples with concerns regarding the ecological impact and recycling of materials. Plastics and composites contribute to a more sustainable approach, with ongoing advancements in recycling technologies addressing the issue of plastic waste.

Design Freedom and Aesthetics – Yet the benefits of plastics and composites extend far beyond lightweight, electrical applications and batteries. These materials offer a world of design possibilities, enabling manufacturers to craft intricate forms for exteriors, interiors, and even powertrain components. They have also revolutionized lighting design and offer exceptional electrical and thermal insulation properties, along with corrosion resistance.

The Adoption Process

Core competence with engineers and designers at automotive OEMs, engineering service providers, and raw material manufacturers have developed methods to create applications using materials based on key engineering performance requirements, manufacturing process requirements, design attributes, and cost considerations.

Identifying Needs and Desires – For adoption of polymer composites follow a structured approach, beginning with the identification of needs and desires, driven by the desire to enhance product performance, productivity, or meet regulatory requirements.

Feasibility Studies – Conduct feasibility studies to determine the technical and economic viability of adopting plastics and composites for a specific application. This study should include an assessment of performance, cost, and the readiness of technology (TRL – Technology Readiness Level).

Developing a Comprehensive Plan – Based on the results of the feasibility study, a technology adoption plan is developed. This plan includes a timeline for implementation, resource requirements, and a budget.

Collaborative Efforts – Suppliers and collaborators are identified based on their capabilities, technical expertise, and experience in research and development.

Employee Training and Integration – Training and development of employees for the new technology, including design, manufacturing processes, and testing.

Ensuring Compliance and Safety – Integrating the technology with existing automotive systems and testing the integrated system for safety and performance compliance with regulations.

New Materials and Applications – Launching materials and their applications for systems while promoting their benefits to customers and stakeholders.

The automotive industry’s embrace of plastics and composites marks a pivotal moment in its evolution. These materials drive innovation, offer design flexibility, durability, and eco-friendly properties, promoting sustainability. As we navigate towards a cleaner and more efficient automotive future, companies are moving ahead with 5R right weighting approach, stand at the forefront. This approach focuses on the Right Material, aligning with the industry’s shift towards lightweighting and sustainable solutions. This will drive a positive change, with innovative solutions in the automotive industry benefiting both society and the environment.

Original source: https://www.tatatechnologies.com/media-center/leveraging-plastics-and-composites-for-a-sustainable-automotive-future/

Author:  Abhay Deshpande, Technical Specialist – Materials, ER&D at Tata Technologies.


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