MATERIALS | AUTOMOTIVE


solutions such as door window frames. Benefits of Schulamid ET100 include: enhanced surface aesthetics; improved durability; suitable rigidity; and a customisable style. Schulamid ET100 GF15 has already been implemented in window frames by Chinese OEM brands. LYB plans to expand the product line’s development and promotion to encompass more automakers and applications.


Recycled grilles Audi has begun mass-producing painted radiator grilles made with recycled content. The grilles, made using polycarbonate (PC) and


Above: LYB has developed PP-based foaming material for the interior of the new Renault Rafale


transportation at LYB. The material includes 20% recycled PP from mechanical recycling, derived from post-industrial waste diverted from the manufacturing process of goods such as flexible packaging. It reduces CO2 emissions compared to using virgin materials. Beyond achieving performance for automotive


exteriors, CirculenRecover polymers offer a mould-in-colour special effect with particles to highlight the use of recycled content. This single- material solution eliminates extra steps, enhances design efficiency, and can help improve the potential recyclability of the parts. Damien Laplane, cross car line and brand


experience leader at Dacia, added: “This serves as a powerful demonstration that recycled materials can be aesthetically pleasing and high performing.” LYB has also collaborated with Renault and Antolin on its Hostacom TYC 2463F E2 foaming material for the interior of the new Renault Rafale. The new PP compound allows interior parts with


elaborate designs, enhanced surface textures, scratch resistance, and low emissions, says LYB. Benefits of the grade include high flowability, an


expanded processing window and high melt strength. A chemical blowing agent also allows for significant weight saving, while the semi-ductile nature of the material extends its use in various interior trim parts. “This material innovation reflects our commit- ment to help craft vehicles that excel in both performance and sustainability,” said Martin. Using the material in serial production is the


result of more than five years of collaboration between the partners.


Both these developments were seen at last


year’s Fakuma – where LYB also launched a new Schulamid grade for the automotive industry Schulamid ET100 is a polyamide-based com- pound product for automotive interior structural


22 INJECTION WORLD | May/June 2025


PET recyclates, are used on the new Audi A3 Sportback and Audi A3 Sedan. They were devel- oped by Audi, plastics converter Winning Plastics, and materials supplier Mocom. “Our objective is to systematically increase the


use of recycled materials in Audi vehicles,” said Frank Fischer of Audi’s materials engineering department. The radiator grille for the new A3 contains “a significant portion” of secondary raw materials for the first time – while meeting high standards in design, appearance, quality and mechanical performance. Suitable recyclates were not available ‘off-the-


shelf’, so Winning Plastics and Mocom developed a recycled compound that partially incorporated painted scrap components from Winning’s produc- tion. “Standard recycling methods for scrap parts


leave too many contaminants and paint residues, making it impossible to reuse the material in a new radiator grille,” said Werner Meschitz, head of innovations at Winning Plastics. “Mocom’s innova- tive process, particularly in paint removal, ensures the required purity of the recyclate, enabling a closed-loop recycling system.” The process begins with scrap production parts – in this case, painted radiator grilles with cosmetic defects such as dust inclusions. These are shred- ded into 30mm pieces, then processed in a hammer mill. Here, the paint is removed through friction, and the debris vacuumed away. The ‘clean’ PC/PET material is then processed into regranulate and blended – at a nominal 27% – into the produc- tion of new radiator grilles.


Circular headlamps Covestro has introduced a new line of post-con- sumer recycled (PCR) polycarbonates made from end-of-life automotive headlamps. Developed in a joint programme initiated by the


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IMAGE: LYONDELL BASELL


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