Engineering Materials

Less is More – Why metal design is not always the optimal solution 

As vehicle electrification accelerates, metal design is not always the optimal solution as it lowers complexity but increases curb weight. To maintain optimal driving experiences, there is a need to decrease the parts weight to compensate for increased battery weight.

To achieve lightweighting , you may extend your toolbox with engineering materials. Plastic solution eases logistics and transportation and allows less secondary operations (no milling/drilling, painting, corrosion protection) with lower energy consumption, less waste streams in production and less hazardous production steps. In the meantime it offers scalability for higher production numbers.

Smart materials selection enabling lower weight and cost

By switching to plastics solutions, you may choose from:

Full plastic

Maximum design freedom

Lowest cost solution

No secondary operations

Multi-material

Metal / Plastic hybrid combing best of two worlds

Metal for energy-absorption

Plastics for integration

Composites

Tailored UD tape solutions with continuous glass or carbon fibers

Suitable for winding, tape placement in the tool or woven structures and consolidated plaques

Free to choose fibers orientation

Collaborating with DSM - your best solution partner in lightweighting

Designing in plastics is not straight forward; many influences determine the best suitable materials. DSM has capabilities to support in every stage if the development process: Advanced part design and CAE calculations, material choice, cost assessment, mold lay-out and prototype/pre-series molding assistance.

Environment

  • Heat
  • Chemicals (oils, glycol, acids)
  • Humidity / Moisture
  • UV

Performance

  • Stiffness
  • Creep resistance
  • Strength
  • Impact
  • Fatigue
  • Tribology 

Design & Processing

  • Functional integration
  • Ribbing
  • Wall thickness
  • Flow length / Wedline
  • Shrinkage / Warpage
  • Tolerances
  • Surface quality
  • Gate location (design)

EV-Hybrid

  • Thermal conductivity
  • Electrical insulative / conductive
  • Electro Magnetic Interference (EMI) shielding
  • High CTI
  • Electro-friendly materials
  • Ecofriendly materials 

Successful customer case study

Browse Key Applications

EPS Steering Housings

Automotive | Steering EPS

Arnite® A (PET) has a long standing track record in brake booster valve housings.

Crankshaft Covers

Automotive | Drivetrain Transmission

Suitable for strict chemical or dimensional stability requirements; Cost effective; Heat resistant; Creep resistant; Oil resistant; Fatigue resistant; Lightweight

Suspension System Spring Seats

Automotive | Body Structural Parts

Arnitel® TPC to be used for jounce bumper dust covers.

Pedals and Pedal Boxes

Automotive | Interior Pedal System

Reliable; Heat resistant; Great surface appearance; Lightweight; Cost effective; High flowability enables thin wall designs

Engine mounts

Automotive | Body Structural Parts

Akulon® Ultraflow 50%GF exhibits a very good fatigue resistance.

More applications

Front End Modules

Automotive | Body Structural Parts

Injection moulding grades can be combined with advanced thermoplastic composites solutions or with metal inserts.

Oil Sumps and Pans

Automotive | Engine Oil / Lubrification

Proven track record with OEMs; Cost effective; Heat resistant; Better welding strength than PA66; Flowability enables thin wall designs

Sunroof frame

Automotive | Exterior Doors

Sunroof frames (low warpage and good flowability)

Sunroof actuators

Automotive |

Higher torque and durability performance than PPA and PA66;Allows more compact actuator design and also lower weight;Comparable performance to specialized materials without the need for expensive additives (e.g., carbon fiber or wear & friction optimizers) creates opportunities for cost savings

Explore DSM grades for lightweighting

ForTii® Ace MX53B

50% Glass Reinforced

ForTii® Ace MX53B is a high Tg PPA combining good toughness at low temperatures and chemical resistance. It is designed to replace metal in structural parts that need high performance over a broad temperature range, from -35°C to above 150°C, both in dry as well as conditioned environment.

ForTii® Ace MX53B is a high Tg PPA combining good toughness at low temperatures and chemical resistance. It is designed to replace metal in structural parts that need high performance over a broad temperature range, from -35°C to above 150°C, both in dry as well as conditioned environment.

ForTii® Ace MX53B is a high Tg PPA combining good toughness at low temperatures and chemical resistance. It is designed to replace metal in structural parts that need high performance over a broad temperature range, from -35°C to above 150°C, both in dry as well as conditioned environment.

  • PA4T
  • Heat Stabilized
  • for Structural Parts

ForTii® Ace MX54B

60% Glass Reinforced

ForTii® Ace MX54B is a high Tg PPA combining good toughness at low temperatures and chemical resistance. It is designed to have a dimensional stability close to aluminum. It has a high mechanical performance over a broad temperature range, from -35°C to above 150°C, both in dry as well as conditioned environment.

ForTii® Ace MX54B is a high Tg PPA combining good toughness at low temperatures and chemical resistance. It is designed to have a dimensional stability close to aluminum. It has a high mechanical performance over a broad temperature range, from -35°C to above 150°C, both in dry as well as conditioned environment.

ForTii® Ace MX54B is a high Tg PPA combining good toughness at low temperatures and chemical resistance. It is designed to have a dimensional stability close to aluminum. It has a high mechanical performance over a broad temperature range, from -35°C to above 150°C, both in dry as well as conditioned environment.

  • PA4T
  • Heat Stabilized
  • for Structural Parts

Xytron™ G4024T

40% Glass Reinforced

Xytron™ is a high performance plastic compound of DSM Engineering Plastics, which is based on PPS (polyphenylene sulphide).

Xytron™ offers extremely good chemical resistance, dimensional stability, intrinsic flame retardancy and high stiffness.

Because of its outstanding properties, Xytron™ contributes to an excellent performance in many different applications.

  • Excellent Mold Release
  • Flame Retardant

Akulon® Ultraflow K-FHG0

50% Glass Reinforced

Akulon® is our family of high performance polyamide 6 and polyamide 66 materials, used by customers across the world in applications ranging from automotive, electronics & electrical, to furniture and packaging.

We offer Akulon® grades for injection molding, blow molding and extrusion (including barrier film, stock shapes, convoluted tubes, and mono and multi filament).

In molded parts the material offers an excellent balance of easy design and processing with outstanding mechanical properties over a wide temperature range and in diverse conditions. Meanwhile for extrusion the strength, resilience and easy processing of Akulon® sets the market standards.

  • Heat Stabilized
  • High Flow
  • Good or high flow

Akulon® Ultraflow K-FG12

60% Glass Reinforced

Akulon® is our family of high performance polyamide 6 and polyamide 66 materials, used by customers across the world in applications ranging from automotive, electronics & electrical, to furniture and packaging.

We offer Akulon® grades for injection molding, blow molding and extrusion (including barrier film, stock shapes, convoluted tubes, and mono and multi filament).

In molded parts the material offers an excellent balance of easy design and processing with outstanding mechanical properties over a wide temperature range and in diverse conditions. Meanwhile for extrusion the strength, resilience and easy processing of Akulon® sets the market standards.

  • High Flow
  • Good or high flow

Contact us for more information

Direct and easy access to our broad portfolio of high-performance plastics: request a quote or order a sample. You can also simply ask our Lightweight experts.

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