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September 2014
An Introduction to the
American Chemistry Council
Plastics and Polymer Composites
TECHNOLOGY ROADMAP for Automotive Markets
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Automakers Face Many Challenges
The automotive industry is seeking ways to cost-
effectively cut weight from vehicles while
maintaining style, performance, and safety
fuel economy standards consumer demands
48.7mpg-
49.7mpg
Source: http://www.epa.gov/otaq/climate/documents/420f12051.pdf *
Plastics and Polymer Composites Are Ready
• Offer unparalleled weight savings
• Provide high energy absorption for improved strength and safety
• Realize alternative powertrain vehicles
• Create value through parts consolidation
• May benefit from natural gas supply boom
Plastics and Polymer Composites Offer Unique Capabilities
Figure 3. Tensile strength versus density for filled plastics, polymer composites,
and metals and metal alloys
Courtesy of Granta Design
Plastics and Polymer Composites Are Already Creating Value in Today’s Vehicles
1. 2014 Chevrolet Corvette Stingray carbon-
fiber-reinforced hood and roof assemblies
2. 2014 Nissan Rogue all-olefinic (i.e., fully
recyclable) liftgate and North America’s
first thermoplastic olefin outer panel
3. Smart Car polycarbonate panorama roof
Bayer polycarbonate and polycarbonate blend material
© General Motors
© Nissan
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3 © Smart USA
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New Technology Roadmap Offers Path Forward
Automotive and plastics
and polymer composites
industries worked together
with guidance of ACC
Plastics Division
VISION: By 2030, the
automotive industry and society
will recognize plastics and
polymer composites as
preferred material solutions
that meet, and in many cases
set, automotive performance
and sustainability requirements.
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Roadmap Offers an Integrated Strategy
Roadmap Offers an Integrated Strategy
Roadmap Offers an Integrated Strategy
Roadmap Offers an Integrated Strategy
Roadmap Offers an Integrated Strategy
Roadmap Offers an Integrated Strategy
Roadmap Offers an Integrated Strategy
Roadmap Offers an Integrated Strategy
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Roadmap Priority Actions
Technology Development Center
Generic Cost Models
Material Properties Database
Design Guidelines
Material and Component Models
High-Speed Manufacturing Center
Joining Techniques
Engineered Materials with
Improved Properties
Education and Training
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Industry-Wide Demonstrations
Technology Development Center
• Establish independent, pre-
competitive technology
development center
• OEMs / suppliers develop and test
concepts at small volumes
Generic Cost Models
• Develop generic cost models
• Demonstrate the cost and benefit of
plastics and polymer composites
compared to alternative materials
The VW XL1 diesel plug-in hybrid uses carbon-fiber reinforced composites for the frame and body and polycarbonate and SABIC polycarbonate glazing material for the side windows for weight savings that help it achieve an estimated 261 mpg.
© Volkswagen
Material Selection & Part
Design
Material Property Database
• Define standard material properties
for automotive applications
• Test data through simulation for
specific automotive system
Design Guidelines
• Establish design guidelines and tools
Material and Component Models
• Develop models that simulate
material behavior
• During and after impact events Cross-section of
polyurethane roof module. Courtesy of Bayer
Manufacturing & Assembly
High-Speed Manufacturing Center
• Manufacturing center or consortium
to advance high-speed processing
Joining Techniques
• Develop technically and economically
viable joining technologies
• Joining similar, dissimilar materials
• Study service, repair, and disassembly
Automotive glazing injection molding machine.
Courtesy of Bayer
Continued Materials
Development
Materials with Improved Properties
• Support development of engineered
plastics and polymer composites with
improved properties
• Develop performance standards to
characterize properties for designers
Carbon fiber laminate plate. Courtesy of BASF
Supporting Initiatives
Education and Training
• Advocate for plastics and polymer
composites training classes
• Advocate for degree programs at
all major universities
Lightweight seating foam. Courtesy of BASF
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Next Steps
ACC works with member companies, automotive industry
partners, researchers, federal agencies, and academia to:
• Build awareness of roadmap priorities among all stakeholders
• Work with Congress to maintain and grow funding for vehicle
lightweighting and safety programs
• Launch collaborative efforts, as appropriate, to address
priority actions and accelerate progress toward innovative
materials and processing approaches
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For More Information
Gina Oliver Senior Director, Automotive Plastics ACC Plastics Division [email protected] www.Plastics-Car.com
Thank You
Matthew Marks, ACC – Plastics Division Automotive Team Chair
Regulatory Marketing Manager for SABIC’s Innovative Plastics [email protected]
The Plastics and Polymer Composites Technology Roadmap for Automotive Markets was prepared by the ACC Plastics Division with input from experts from
automotive OEMs, Tier suppliers, plastics and polymer composites providers, researchers, federal agencies, professional societies, and consultants.
