Which Plastics Are Used by Car Manufacturers?
Whilst metal is an integral component of automobiles and most parts are metal-made, some metal properties are not conducive as they lack the required lightness, non-conductivity, heat resistance and flexibility that some features need.
When Leo Baekeland invented synthetic plastics in 1907, automobile production would never be the same again. Bakelite, as it was called, was the ideal material for some automobile parts, such as instrument panels, control surfaces and engine elements where strength, heat resistance and non-conductivity were greatly needed.
Today, high-performance polymers with better properties replace Bakelite and significantly increase a vehicle’s reliability, safety and performance. Automotive plastics are lightweight and cheap, which makes them a choice material for automobile manufacturers. This is because weight reduction improves a car’s fuel efficiency and speed whilst remaining safe and durable.
Car manufacturers don’t just use engineering plastics. The automobile industry follows stringent requirements and regulations to ensure the parts and the car are compliant, durable and adhere to safety and hazard protocols. In the manufacturing industry, this is known as the material qualification process. Car manufacturers must ensure that their parts and materials pass the standards of this qualification process.
This blog post covers the types of plastic used in cars and car parts and why plastic manufacturers in Sydney choose these materials. Let’s take a look at these engineering plastics.
Why Is Plastic Used in Car Manufacturing?
The car industry has seen a lot of innovations since its inception. Nowadays, cars are much cheaper but more durable, fuel-efficient and have better overall performance. We attribute most of these innovations to the use of high-grade automotive plastics.
The average modern car has approximately 20% engineering plastic parts both in the interior and exterior, which tells of the importance of automotive plastics nowadays. Here are some of the advantages of engineering plastic in car manufacturing:
Plastics Reduce Car Weight
High-grade polymers significantly reduce the weight of a car. This is crucial as it makes the vehicle more fuel efficient and reduces the release of greenhouse gases, making it more environmentally friendly.
For instance, a modern car’s weight can be reduced by 100 kg, which results in a decrease in fuel consumption of about 0.4 litres per 100 km. This also increases travel distance whilst being cost-efficient. Also, it reduces CO2 emissions by about 10 g per km, reducing your car’s carbon footprint.
Plastics Improve Car Safety
Surprisingly, certain polymers are much more durable and stronger than other metals, which is why some are essential components in car parts that absorb impact, such as bumpers. These bumpers have glass fibres incorporated with polymers, such as polycarbonate (PC), polypropylene (PP), acrylonitrile butadiene styrene (ABS), polyurethane (PUR) and polyamide (PA). They weigh 50% less than alternative materials and can absorb four to five times the impact.
In addition, seatbelts, airbags, the child seat and even glass are made from high-grade polymers and plastics that make the car safer for the driver and passengers.
Plastics Cut Down Car Manufacturing Costs
Vehicle assembly time and costs have significantly reduced over the years due to the introduction of single mould components and other design conventions and innovations. These plastic parts are also corrosion-resistant and are less likely to fail due to their seamless designs.
Plastics Improve Automobile Design
Automotive plastics allow car designers and engineers to develop new design conventions and innovations that were not possible a few decades ago. This is thanks to the versatility and flexibility of engineering plastics.
With great design also comes an improvement in functionality. Lesser metal parts significantly increase a car’s shelf life and make it weather-resistant. Plastic parts are also easier to replace and repair than metal parts.
Plastics Make Cars Comfortable
Other than updating the exterior design of an automobile, the interior has also seen much improvement due to engineering plastics. These improvements include comfortable seats that are form-fitting, acoustic amplification, better steering wheel grip and infrared ray filtration to keep the car cooler during hot days.
What Plastics Are Car Parts Made of?
Now that you know the various advantages of using engineering plastics, let’s look at some of the specific polymers and plastics that comprise automotive plastics:
Polypropylene—This is a more common engineering plastic used for automobile parts due to its flexibility and ability to be formed into any shape. This plastic type is also known for its superior heat and chemical resistance. It is frequently found in car bumpers, carpet fibres and gas canisters.
Polycarbonate—This polymer is lightweight and has high-impact absorption features, which is why it’s commonly used in fenders and headlamps. Its weather resistance is also essential for better overall performance and fuel efficiency.
PVC Plastic—Polyvinyl chloride is known for its flame resistance which is why it is found in interior components, such as dashboards, consoles, door coverings and more. It is also formable into stiff and flexible parts.
ABS Plastic—Acrylonitrile butadiene styrene plastic is suitable for manufacturing parts for safety due to its impact absorption and energy redistribution during collisions. This plastic is durable, heat resistant and ideal for dashboard components and steering wheel coverings.
Polyethylene—This plastic is known for moisture resistance, impact resistance, low density and durability. It’s ideal for electrical insulation and glass-reinforced bodies.
Nylon 6/6—Nylon 6/6 is a versatile plastic with excellent wear resistance and stability. It’s also waterproof, which makes it suitable as coatings, and formable in different shapes via extrusion. Nylon is quick to produce and affordable.
McNeall Plastics: Helping Businesses Through Plastic Engineering and Manufacturing
The proper engineering plastic material can make a difference when manufacturing automobile parts. This ensures durable, flexible, versatile and better components that suit a vehicle’s needs, such as hauling, construction or simply transporting.
The proper engineering plastics suppliers are also essential, as this can significantly reduce production costs, save time and increase profit margins. If you’re looking for plastic machining in Brisbane that can provide you with a custom formula or casting, then McNeall Plastics is the right partner for your company. McNeall Plastics is the leading plastic manufacturer in Australia and the exclusive developer and manufacturer of the world’s number one nylon, AUSTLON®. For your CNC manufacturing needs and services, contact us and let us help you.