SHEET MATERIALS | MATERIALS
Plastic sheet boosts engineering designs
Recent
developments in sheet include new roofing in a US shopping mall, storing de-icing fluids at an airport, and multiple roles in two different designs of futuristic car
Plastic sheet has long been specified as a roofing material – offering many advantages over glass – but has also found its way into applications such as concept cars, as a lightweight and durable material. For instance, polycarbonate sheet from Exolon has helped bring a self-driving car to life. The Self-Driving Urban E-Shuttle (SUE) recently saw its premiere at the UE Studios of Uedelhoven Gaimersheim in Germany. As a materials partner, Exolon supplied transparent solid polycarbonate sheets for its glazing, roof, and B-pillar structures. The glazing – including windshield, rear window, and side windows – is made of transparent solid polycarbonate sheets with a thickness of 5mm. These ensure clear, distortion-free visibility, high impact resistance and reduced weight compared to glass. In the roof area, a 6mm thick polycarbonate sheet in a grey tint is used. It is made from a plant-based raw material granulate and is ISCC PLUS certified. An IR absorber in the raw material also reduces interior heat build-up under strong sunlight.
Another defining design element is the vehicle’s B-pillar cover, which was extruded from a special polycarbonate compound in a brown-orange
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shade. The 6mm thick sheet combines functional stability with a distinctive visual impact. The materials are also easy to thermoform, allowing them to be adapted to the design. In combination with low weight, this opened up additional structural and creative freedom, say Exolon.
SUE is an autonomous, electric people-mover designed to shape the public transport systems of tomorrow. It was developed by a consortium of 10 partners, including TÜV Nord Mobilität and Fraunhofer EMFT.
Polycarbonate façade Prior to this, Exolon launched its new multi-panel 60 HX translucent façade at K2025. The high-performance polycarbonate panel with a thickness of 60mm and the innovative Hybrid-X structure sets new standards in terms of thermal insulation, mechanical strength and energy-effi- cient construction, says the company. The tongue-and-groove system enables a quick,
clean and visually homogeneous installation – for spacious, light-flooded areas with clear lines. There is also an EcoPlus variant, in which a large
May/June 2026 | FILM & SHEET EXTRUSION 13
Main image: Exolon has supplied transparent polycarbonate sheets for the SUE self-driving car
IMAGE: EXOLON
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