Plastic Revolution in Automotive

Plastic materials have taken a place in every aspect of our lives. Initially used only in simple consumer products, plastics have become indispensable in the industrial world. In 2023, more than 410 million tons of plastics were produced worldwide.

With the continued increase in the amount of production, more than 450 million tons of plastics are expected to be produced by the end of 2025.

The use of plastics in the automotive industry continues to increase in parallel with other sectors.

Factors such as lightness, cost advantages and design flexibility are the most important reasons for this increase, but with the introduction of electric vehicles, the sector's need for plastic material solutions in part designs can also be cited as one of these reasons.

Polymer pyramid listing high-performance polymers used in TS processes organized from amorphous to crystalline. Modified from Friedrich, K., 2018. Polymer composites for tribological applications. Advanced Industrial and Engineering Polymer Research

Plastics are classified according to many different criteria, from production methods to processing processes, from performance characteristics to molecular structures, and are divided into certain groups. The thermal behavior of plastics is one of the most important classification criteria as it plays a key role in determining the production method.

According to their thermal behavior, plastics are divided into three groups: thermoplastics, thermosets and elastomers.

• Thermoplastics: Plastics that soften when heated and harden again when cooled. They are the most widely used type of plastic in automotive because they are recyclable.

  
  

• Thermosets: Once shaped, they cannot be reshaped. They are preferred in applications requiring high temperature and mechanical strength.

  
  

• Elastomers: For a long time they were considered in the thermoset group, but with the discovery of thermoplastic elastomers, they are now considered a new group. Since the glass transition temperature (Tg) of these materials is below room temperature, they have high ductility and mobility.

As sectors such as automotive, aerospace and aerospace require high mechanical properties with lower specific gravity, the need for advanced engineering plastics is increasing.

Evolution of Plastics in Automotive

The widespread use of plastics in automotive began in the mid-20th century.

• 1900s: With the discovery of bakelite, plastics began to be used in the industrial industry.

• 1950s: Plastics were first used in automobile interior trim parts.

• 1970s: With the impact of the oil crisis, plastics with low specific gravity such as polypropylene (PP) and polyurethane (PU) began to be preferred in order to save fuel.

• 1990s: With mineral, glass fiber and carbon fiber reinforced plastic materials, plastics with low specific gravity and high strength began to be developed. Today, R&D studies using advanced engineering plastics and recyclable composite materials stand out in line with current trends.

  
  

Trends in Automobile Plastics

The automobile industry has changed dramatically and the pace of change has accelerated in recent years. Today, the modern automobile is not only a design and engineering miracle but also a technological one.

Many innovations such as the electrification of the automotive industry, increasing software configurations in vehicles, the spread of autonomous vehicles, sustainability goals, the impact of artificial intelligence and machine learning, the increase in connected vehicles (IoT) and the preference for 3D printed parts have revolutionized the industry. Here are some of these innovations;

Tailgate prototype made from SABIC-STAMAX™ long glass fiber

In today's automotive industry, vehicle tailgates are usually manufactured from steel materials. However, in recent years, thanks to advances in technology and materials science, plastic tailgate designs have come to the fore. Plastic recycled composite plastic tailgates, which are used instead of steel panels, provide 15% emission reduction and 20% energy savings.

This innovation not only increases the fuel efficiency of vehicles but also gives them a modern and aesthetic appearance. The use of lightweight materials in the automotive world is developing rapidly and we are likely to see more of them in the future.

In the automotive industry, vehicle dashboards are undergoing a major transformation. Many modern vehicles now use curved plastic instrument panels with software-integrated large screens. These panels offer many advantages both aesthetically and functionally, providing a superior experience for drivers and passengers. These digital dashboards offer drivers and passengers many advantages, including modern design, wide-angle view quality, software integration, design flexibility and versatility.

Curved digital instrument clusters with software-integrated widescreen displays have become an indispensable part of modern vehicles. These panels provide the driver with a safer, more comfortable and enjoyable driving experience with the advantages they offer in terms of both design and technology.

Vehicle designs are not only limited to performance and comfort but also stand out with innovative solutions that combine technology and aesthetics. In this regard, new generation front bumper lighting systems have become an important trend that both increases the visual appeal and improves the functionality of vehicles. These systems are integrated into the front bumper of the vehicle, offering a seamless lighting experience across the entire body.

In the automotive world of the future, lighting systems are expected to become even more intelligent and integrated. These developments aim to offer drivers a safer, more comfortable and personalized driving experience. It is known that plastic materials have a very important position in the use of such trending technologies.

Average Vehicle Structure (BIW & Closures) - Material Distribution by empty weight per vehicle

In the automotive industry, which is considered one of the most important industries in the world, plastic materials are likely to continue to play a key role in the future of the sector due to their cost and sustainability advantages.

Sources:

1. Shashank M. Abhay V.: Center for Automotive Research, Ann Arbor, Michigan USA,

2. Beyond the hype. (2017). KPMG. Retrieved from https://assets.kpmg/content/dam/kpmg/xx/pdf/2017/05/beyond-the-hype.pdf

3. Advanced Polymeric Coatings and Their Applications: Green Tribology January 2019 DOI:10.1016/B978-0-12-803581-8.11466-3