Sustainability, a critical aspect in plastics components

Dirk Tietz, Head of Automotive at igus subsidiaries, explains that the company develops a wide variety of plastic compounds with which it produces bearings and energy chains using the injection moulding process. ‘Depending on the area of use (interior or exterior) and the applications, e.g. vehicle seats or coolant pumps, different materials or others from our iglidur brand are recommended. Here, igus covers a wide range of application conditions. From low moisture absorption and high temperature materials to chemical resistance and low coefficient of friction. It is usually a challenge to identify the most significant polymers. The main goal is always to identify the cheapest solution that works,’ says Tietz. Article published in AutoRevista 2.399

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‘The current discourse and evaluation procedures regarding the limitation of perfluorinated and polyfluorinated alkylated substances (PFAS), together with PTFE, have prompted an increasing number of companies in the European Union to explore alternative solutions to conventional metal composite (DU) bearings,’ says Tietz. He adds: ‘At igus, we have developed a range of bearing materials that comply with PFAS restrictions and are free of PTFE, in line with the current regulatory landscape. The field of plastic bearing technology is undergoing further development, focusing on the electrical conductivity of plastics. The aim is to replace metallic bearings that are installed in assemblies that undergo cathodic electroplating (e-coating) and therefore have to be electrically conductive. For example, igus offers the material iglidur F300. The topic of hysteresis behaviour for the application of plastic plain bearings in solenoid valves also plays an important role in the development of materials”.

‘As part of our commitment to environmental responsibility, we have set ourselves the clear goal of making our buildings and production CO2 neutral by the end of 2025. In addition to this overall goal, we are involved in several projects and initiatives that comprehensively examine the life cycle of technical plastics, covering production, use and end-of-use management. As part of our Chainge programme, we offer customers, including those in the automotive industry, a free disposal service for used or worn plastic products such as energy chains, semi-finished products, plastic gears or plastic plain bearings. Chainge cleans and recycles these products and reuses them to manufacture new technical products,’ he says.

Tietz says: ‘The future of plastics in the automotive sector is expected to be characterised by a combination of sustainability and efficiency, driven by technological innovation. Demand is expected to increase, especially in the field of plastic bearing technology, due to the importance of weight, especially in the context of e-mobility. Consequently, more attention will be paid to plastic bearings. From a sustainability point of view, the absence of lubricants is increasingly significant. In addition, the ability to incorporate design elements into plastic bearings, thereby reducing the space required for installation, is a significant advantage. The cost-effectiveness of plastic plain bearings is another crucial factor, as it contributes to their overall competitiveness in the market. It is imperative to recognise the possible implications of legal regulations that could lead to the regulation of PFAS and PTFE,’ concludes the Head of Automotive igus subsidiaries.

Environmentally friendly materials

Pedro Navarro, managing director of Polisol Plásticos, SL and its partner Sinclair & Rush, explains that many plastics and composites are used both indoors and outdoors to improve the performance, safety and aesthetics of modern vehicles. Examples include plastics such as polypropylene (PP), used in bumpers and model fibres for its light weight, resistance to chemicals, heat resistance and cost-effectiveness. In this sense, they also point to polycarbonate (used in headlamp lenses, bumpers and panels), polyvinyl chloride (PVC, used in dashboards, car body parts), or Acrylonitrile Butadiene Styrene (ABS, used in steering wheel covers, dashboards and body parts). Composites also stand out, such as Carbon Fibre Reinforced Polymer (CFRP, used for body panels, roof structures and interior trim); Glass Fibre Reinforced Polymer (GFRP, used in body panels, bumpers and some structural components); and also natural fibre composites, used for example in interior panels or seat backs for their sustainability, lightness and good mechanical properties.

Navarro emphasises ‘increasing the use of bioplastics derived from renewable resources such as corn starch, sugar cane and algae’; and pointing out a margin for improvement ‘with 100% biodegradability and a lot of work pending to match the performance of traditional plastics’. In the case of advanced composites, they highlight the integration of carbon fibres, glass fibres and nanoparticles to create stronger and lighter materials, bearing in mind that in this case ‘production costs must be aligned with industry standard bills of materials’ and that ‘a broader scope is required across the industry’. 

Finally, and in terms of smart and functional materials, they highlight the introduction of ‘self-repairing’ plastics with superior durability and advanced functionality, whose margins for improvement go through ‘increasing market awareness and boosting profitability for end users’. The Polisol and Sinclair&Rush representative points to the ‘emphasis on green materials and recycling technologies’; ‘the use of lightweight materials to improve fuel efficiency and support electric vehicle (EV) performance’, the ‘development of materials that support advanced driver assistance systems (ADAS) and connectivity features’, the ‘adoption of additive manufacturing (3D printing) and other advanced production methods’. All these trends, he believes, ‘are driving the automotive industry towards more sustainable, efficient and innovative solutions’.

Navarro comments that ‘although we supply plastics and rubber to automotive manufacturers and sub-tier suppliers (Tier 1-3) of these same OEMs, the products are generally and mostly for temporary use and do not remain in the vehicle. We are also a manufacturer and supplier of masking components, which are used to package, protect and finish critical components from contamination, moisture and damage during the manufacturing, assembly and shipping processes (also known as consumable components or items). Although our products may be considered a ‘throw-away’ item, they remain fundamental to the overall design and construction of any motor vehicle, whether passenger, commercial, off-road, highway, special, military, public transport or recreational. To mention just two developments, we are already working with a bio-organic based polymeric plasticiser for our flexible products and a sustainable thermoplastic compound committed to 100% recycling of household waste, for our semi-rigid components. Of course, there are other material developments in the pipeline that will help us reduce our carbon footprint and greenhouse gas emissions, while supporting the circular economy: the 3Rs principle: Reduce, Reuse, Recycle”.

‘Plastics in the automotive industry have been, are and still appear to be promising, with a strong focus on sustainability, innovation, continuous improvement and efficiency. These trends are set to transform the way vehicles are designed, manufactured and recycled, leading to a more sustainable and high-performance automotive sector,’ concludes Pedro Navarro (Polisol).