{"id":35503,"date":"2026-01-27T10:12:38","date_gmt":"2026-01-27T02:12:38","guid":{"rendered":"https:\/\/firstmold.com\/?p=35503"},"modified":"2026-03-04T13:33:09","modified_gmt":"2026-03-04T05:33:09","slug":"automotive-plastic-materials","status":"publish","type":"post","link":"https:\/\/firstmold.com\/ko\/tips\/automotive-plastic-materials\/","title":{"rendered":"\uc790\ub3d9\ucc28 \uad6c\uc870 \ubd80\ud488\uc744 \uc704\ud55c \ud601\uc2e0\uc801\uc778 \ud50c\ub77c\uc2a4\ud2f1 \uc18c\uc7ac"},"content":{"rendered":"\n<p id=\"h-\">In modern automobiles, plastic makes up around 15-20% of the car\u2019s weight, although it can account for up to 50% of the volume <sup><a href=\"#ref01\">[1]<\/a><\/sup>. The application of plastics in the automobile industry has continued to increase over the years, driven by the push by automakers towards lightweighting.<\/p>\n\n\n\n<p>Making vehicles lighter helps to improve fuel economy. With the shift towards new energy vehicles (NEVs), lightweighting is key to quelling range anxiety. It is projected to make up 30% of vehicle weight by 2030. Modern vehicles use plastics for both external and internal structural components. Consequently, the classification of automotive materials is based on their usage as follows;<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong><em>Automotive plastic materials for exterior parts:<\/em><\/strong> They can play aesthetic and functional roles. Because of their location, they need to be weather resistant (e.g., UV resistant), have high impact strength, and have a desired appearance. Examples of external components made with plastic are grilles, bumpers, spoilers, and door handles.<\/li>\n\n\n\n<li><strong><em>Plastics for interior parts:<\/em><\/strong> Plastics used in vehicle interiors can also play decorative or functional roles. They are expected to have low volatile organic compounds, which is crucial for indoor air quality <sup><a href=\"#ref02\">[2]<\/a><\/sup>. Other important properties of plastic automotive materials for interior parts include comfort and scratch resistance. Examples include door panels, dashboards, center consoles, and air vents.<\/li>\n\n\n\n<li><strong><em>Plastic materials for automotive structural parts:<\/em><\/strong> They are also referred to as under-the-hood plastics. Their primary property is high chemical, heat, and wear resistance, because they operate in an extreme environment. Air intake manifolds and engine covers are examples of under-the-hood parts made with plastic. &nbsp;<\/li>\n<\/ul>\n\n\n\n<figure class=\"wp-block-image aligncenter size-full\"><img fetchpriority=\"high\" decoding=\"async\" width=\"1200\" height=\"675\" src=\"https:\/\/firstmold.com\/wp-content\/uploads\/2026\/01\/Plastic-Materials-For-Automotive-Structural-Parts.webp\" alt=\"Plastic Materials For Automotive Structural Parts\" class=\"wp-image-35507\" srcset=\"https:\/\/firstmold.com\/wp-content\/uploads\/2026\/01\/Plastic-Materials-For-Automotive-Structural-Parts.webp 1200w, https:\/\/firstmold.com\/wp-content\/uploads\/2026\/01\/Plastic-Materials-For-Automotive-Structural-Parts-300x169.webp 300w, https:\/\/firstmold.com\/wp-content\/uploads\/2026\/01\/Plastic-Materials-For-Automotive-Structural-Parts-1024x576.webp 1024w, https:\/\/firstmold.com\/wp-content\/uploads\/2026\/01\/Plastic-Materials-For-Automotive-Structural-Parts-768x432.webp 768w, https:\/\/firstmold.com\/wp-content\/uploads\/2026\/01\/Plastic-Materials-For-Automotive-Structural-Parts-18x10.webp 18w, https:\/\/firstmold.com\/wp-content\/uploads\/2026\/01\/Plastic-Materials-For-Automotive-Structural-Parts-600x338.webp 600w\" sizes=\"(max-width: 1200px) 100vw, 1200px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-considerations-for-exterior-automotive-parts-design-and-material\"><strong>Considerations for Exterior Automotive Parts Design and Material<\/strong><\/h2>\n\n\n\n<p>The design of exterior automotive parts using automotive injection molding materials must strike a balance between operational efficiency, aesthetic appeal, and long-term viability. Designers must consider standardization, serialization, and communalization to improve quality and lower costs.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong><em>Standardization:<\/em><\/strong> Using standard, off-the-shelf parts or sticking to industry-standard dimensions lowers design time and improves compatibility.<\/li>\n\n\n\n<li><strong><em>Serialization:<\/em><\/strong> Using the same base design to produce different sizes or capabilities improves economies of scale.<\/li>\n\n\n\n<li><strong><em>Communalization:<\/em><\/strong> Using identical parts, like the same door handles, across different car models reduces complexity and promotes easier maintenance.<\/li>\n<\/ul>\n\n\n\n<p>The Engineering principles of rationality, advancement, ease of maintenance, reliability, economy, and manufacturability must also be put into consideration to ensure the part is cost-effective, durable, and functional.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>Engineering principles<\/th><th>Impact on manufacturing<\/th><\/tr><tr><td>Rationality<\/td><td>Design should be logical and purposeful to seamlessly fit into the environmental application.<\/td><\/tr><tr><td>Advancement<\/td><td>Incorporating new automotive materials like weather-resistant composites ensures the part is future-proof.<\/td><\/tr><tr><td>Reliability<\/td><td>External parts should be robust and durable to withstand environmental stressors throughout their lifecycle.<\/td><\/tr><tr><td>Ease of Maintenance<\/td><td>Automotive parts should be designed to be easily cleaned or inspected. For example, using modular designs can lower future upkeep costs.<\/td><\/tr><tr><td>Economy<\/td><td>The choice of automotive materials must balance performance and cost-effectiveness.<\/td><\/tr><tr><td>Manufacturability<\/td><td>Part design must take the production process into consideration. For example, shapes can be simplified based on the flowability of the material to make injection molding easier.<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-why-plastic-is-used-for-automotive-parts-manufacturing\"><strong>Why Plastic is Used for Automotive Parts Manufacturing<\/strong><\/h2>\n\n\n\n<p>Several key factors impact the increasing use of plastic materials for automotive structural parts. Lightweighting remains at the top of those factors. Achieving weight reduction has given a boost to car fuel economy. The lighter the car, the lower the amount of energy it will require to move. Other factors that favor the use of plastics for automotive parts include:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong><em>Safety concerns:<\/em><\/strong> New automotive materials are engineered to better absorb and redistribute energy during an impact. Softer bumper materials, for example, reduce injury risks in low-impact crashes compared to rigid bumpers.<\/li>\n\n\n\n<li><strong><em>Suppression of noise and vibration:<\/em><\/strong> Plastics absorb vibrations, which helps with noise suppression. With plastics, automakers can eliminate the extra weight that comes with using sound-dampening materials to achieve the same effect. This makes driving quieter and more comfortable.<\/li>\n\n\n\n<li><strong><em>Aesthetics and design flexibility:<\/em><\/strong> Plastics can be molded into complex shapes using precision molding techniques. Consequently, automakers have the flexibility to create complex, aesthetically pleasing designs, eliminating the need for costly secondary processing.<\/li>\n\n\n\n<li><strong><em>Weatherproofing:<\/em><\/strong> Many automotive new materials are engineered to improve properties like resistance to corrosion, chemicals, UV damage, rust, and extreme temperatures. These improved properties increase their durability in real-world applications.<\/li>\n\n\n\n<li><strong><em>Environmental impact and sustainability:<\/em><\/strong> The focus of the automotive industry is shifting towards sustainability. Recycled plastics are increasingly being incorporated into vehicle parts because they are easily recycled. Also, the manufacturing process of plastic is usually less energy demanding compared to metal production.<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-material-requirements-for-common-automotive-exterior-parts\"><strong>Material Requirements for Common Automotive Exterior Parts<\/strong><\/h2>\n\n\n\n<p>The combination of safety regulations, harsh environmental exposure, manufacturing efficiency, and aesthetic requirements affects the choice of material used for automotive external parts. For example, external automotive parts are exposed to environmental factors like UV, temperature extremes, and chemical exposure.<\/p>\n\n\n\n<p>Besides the environmental factors, external parts are also exposed to mechanical factors like abrasion and impact. Therefore, they need to be made with automotive materials that maintain their shape over the lifecycle of the vehicle and withstand structural load.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>External automotive parts<\/th><th>Preferred automotive plastic materials<\/th><th>Key properties<\/th><\/tr><tr><td>Bumpers, trims, liners<\/td><td>Polypropylene (PP)<\/td><td>Lightweight, chemical-resistance, tough<\/td><\/tr><tr><td>Headlights, grilles, spoilers<\/td><td>Polycarbonate (PC)<\/td><td>UV resistance, high impact resistance, transparent<\/td><\/tr><tr><td>Bumper covers, sealings<\/td><td>Thermoplastic Polyolefin (TPO) or Thermoplastic Elastomer (TPE) or Thermoplastic Vulcanizate (TPV)<\/td><td>Flexible, impact-absorbing, elastic<\/td><\/tr><tr><td>Mirror housings, grilles<\/td><td>Acrylonitrile Butadiene Styrene (ABS) or ABS + PC<\/td><td>High strength, glossy finish, rigid<\/td><\/tr><tr><td>Splash guards, fender liners<\/td><td>Polyethylene (PE)<\/td><td>Highly durable, moisture-resistance<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-material-requirements-for-bumpers\">Material Requirements for Bumpers<\/h3>\n\n\n\n<p>Modern automotive bumpers are complex structures that incorporate electronic components like cameras and sensors. Additionally, it is expected to meet regulatory safety requirements. Consequently, automotive materials for bumpers are expected to balance impact absorption, durability, structural strength, and cost-effectiveness.<\/p>\n\n\n\n<p>The primary material commonly used for injection-molding bumper outer shells is polypropylene. It is preferred because it is lightweight, flexible, and resistant to impact and chemicals. To improve its rigidity and impact resistance, it is often modified with fillers or rubber, e.g., Thermoplastic Olefins (TPO).<\/p>\n\n\n\n<p>The bumpers of premium or high-end vehicles are usually made from a PC+ABS blend. This material hybrid offers superior head stability, toughness, and surface quality compared to pure PP. The recommended surface treatment will vary depending on the material used to make the bumper.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>Bumper automotive material surface treatment<\/th><th>PP<\/th><th>PC+ABS<\/th><\/tr><tr><td>Cleaning<\/td><td>Requires thorough cleaning for wax or grease removal, followed by soft sanding<\/td><td>Light sanding with 400-600 grit sandpaper to create a mechanical key<\/td><\/tr><tr><td>Activation<\/td><td>The surface is oxidized by passing a gas flame over it. This increases surface energy.<\/td><td>Usually not required. However, the surface is sometimes heated at 60 \u00b0C for 60 mins for stability.<\/td><\/tr><tr><td>Adhesion promoter<\/td><td>A PP-specific specialized chemical primer must be applied to create a bondable interface.<\/td><td>Epoxy or a flexible plastic primer is used to create a consistent base<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-automotive-plastic-materials-for-vehicle-lights\">Automotive plastic materials for vehicle lights<\/h3>\n\n\n\n<p>Automotive injection molding materials for vehicle lighting must possess a combination of great thermal stability, high optical transparency, weather resistance, and impact resistance. Modern automotive lighting is mostly made from specialized thermoplastics for design flexibility and lightweighting.<\/p>\n\n\n\n<p>The requirements for the various automotive lighting parts are different. For example, the lenses are expected to have high light transmittance, UV stability, as well as impact and chemical resistance. The material for headlights and fog lights must withstand high thermal load (100 \u00b0C to 190 \u00b0C). Taillights, on the other hand, require automotive plastic materials with <a href=\"https:\/\/firstmold.com\/tips\/design-for-moldability\/\" type=\"post\" id=\"26783\" target=\"_blank\" rel=\"noreferrer noopener\"><strong>high moldability<\/strong><\/a> for complex shapes.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>Lighting component<\/th><th>Recommended automotive material<\/th><th>Desirable properties<\/th><\/tr><tr><td>Headlight and fog light lenses<\/td><td>Polycarbonate (PC)<\/td><td>High heat resistance (over 130 \u00b0C) and excellent impact resistance.<\/td><\/tr><tr><td>Taillight lenses<\/td><td>Acrylic (PMMA)<\/td><td>Better UV resistance and scratch resistance.<\/td><\/tr><tr><td>Housing<\/td><td>Modified PP, e.g., mineral-reinforced nylon (PA6\/66)<\/td><td>Lightweight, high structural and chemical resistance, cost-effective<\/td><\/tr><tr><td>Reflectors<\/td><td>Bulk molding compound<\/td><td>High-dimensional stability at extreme heat (over 150 \u00b0C)<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p>Surface treatment is a crucial part of automotive lighting. The treatment can either enhance the performance or the lifespan of the plastic component. Below are common treatments for different automotive lighting components.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong><em>UV-Resistant Coating:<\/em><\/strong> This treatment is mandatory for PC headlights to prevent degradation from solar exposure.<\/li>\n\n\n\n<li><strong><em>Scratch resistance coating:<\/em><\/strong> Hard coating is applied to PC to increase its resistance to scratches from road debris and washing.<\/li>\n\n\n\n<li><strong><em>Vacuum metalizing:<\/em><\/strong> This treatment is applied to reflectors to make them reflective.<\/li>\n\n\n\n<li><strong><em>Hydrophobic coating:<\/em><\/strong> Anti-fog coating enhances visibility in wet conditions by repelling water.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-automotive-material-requirement-for-grilles\">Automotive Material Requirement for Grilles<\/h3>\n\n\n\n<p>Grilles play aesthetic and functional roles. Therefore, automotive plastic materials for grille production must balance durability with aesthetic appeal. The reason is that they are constantly exposed to harsh environmental conditions, road debris, and engine heat.<\/p>\n\n\n\n<p>Other qualities automotive materials for grilles are expected to have include dimensional stability, good surface finish, UV resistance, and lightweight. The most common material for grilles is ABS. It is favored for high impact resistance, rigidity, and ease of molding complex shapes.<\/p>\n\n\n\n<p>Acrylonitrile styrene acrylate (ASA) is a great alternative to ABS. Black, textured grilles are mostly made with PP because it is cost-effective and can resist temperatures up to 130 \u00b0C. Popular surface treatments include electroplating, painting, UV coating, texturing, and plasma treatment. The exact surface treatment will depend on the material and what the manufacturer wants to achieve.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>Grille component<\/th><th>Material<\/th><th>Surface treatment<\/th><\/tr><tr><td>Mesh or Frame<\/td><td>ABS or ASA<\/td><td>Electroplating or painting for gloss or matte<\/td><\/tr><tr><td>Chrome trim<\/td><td>ABS<\/td><td>Chrome plating<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-automotive-materials-for-wheel-housing-liners\">Automotive Materials for Wheel Housing Liners<\/h3>\n\n\n\n<p>The splash shields or inner fender liners are designed to protect the engine, body, and structural parts from debris and moisture. They are subject to severe environmental stress and constant abrasion from road debris.<\/p>\n\n\n\n<p>The automotive injection molding materials for wheel housing liners are expected to have high impact and corrosion resistance, temperature stability, chemical resistance, durability, and contribute to noise reduction.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>Wheel housing liner automotive materials<\/th><th>Ideal use<\/th><\/tr><tr><td>Thermoplastic Olefin<\/td><td>Widely used because it balances flexibility, durability, and resistance to cracking in cold weather.<\/td><\/tr><tr><td>High-Density Polyethylene<\/td><td>Best for situations where impact resistance must be balanced with lightweight and cost-effectiveness.<\/td><\/tr><tr><td>Ethylene Propylene Diene Monomer (EPDM)<\/td><td>Used for trucks and extreme climates. It offers superior flexibility, UV resistance, and noise dampening.<\/td><\/tr><tr><td>Nonwoven Polyester\/Felt<\/td><td>Used in premium vehicles to achieve excellent noise reduction.<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p>Surface treatment for automotive plastic materials for wheel housing liners is either done to prevent, enhance, or repair them.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong><em>UV-Stabilized coatings:<\/em><\/strong> To prevent cracking, fading, and brittleness from prolonged sun exposure.<\/li>\n\n\n\n<li><strong><em>Hydrophobic coatings:<\/em><\/strong> Applied to rejuvenate dull plastic.<\/li>\n\n\n\n<li><strong><em>Adhesive coatings:<\/em><\/strong> Used mostly on the rear side of the felt to ensure it sticks properly to the wheel housing to prevent gaps.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-automotive-materials-for-wheel-covers\">Automotive Materials for Wheel Covers<\/h3>\n\n\n\n<p>The wheel cover is constantly exposed to road debris and environmental factors like heat, road salt, and UV from the sun. Therefore, automotive plastic materials for wheel covers must be highly durable and resistant to impact and corrosion.<\/p>\n\n\n\n<p>The commonly used material is ABS. It is cost-effective, lightweight, and highly resistant to corrosion. Polycarbonates are best for harsh weather conditions or off-road applications because of their superior impact resistance.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>Wheel cover treatment<\/th><th>Purpose of surface treatment<\/th><\/tr><tr><td>Chrome plating<\/td><td>It is a popular finish for ABS that provides a shiny and premium finish.<\/td><\/tr><tr><td>Clear coating<\/td><td>UV resistance treatment that prevents yellowing and fading from long-term sunlight exposure.<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-automotive-plastic-materials-for-radiator-grilles\">Automotive Plastic Materials for Radiator Grilles<\/h3>\n\n\n\n<p>Radiator grilles serve the dual purpose of protecting the radiator and enabling air intake for cooling the engine. ABS and carbon fiber are the two recommended materials for radiator grilles. They are lightweight and resistant to environmental stressors.<\/p>\n\n\n\n<p>ABS radiator grilles usually go through chrome plating to enhance their aesthetics and provide a high-shine finish. UV inhibitor coating is another common treatment to prevent cracking, yellowing, and degradation from UV exposure.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>Automotive material<\/th><th>Durability<\/th><th>Corrosion resistance<\/th><th>Weight<\/th><th>Best use case<\/th><\/tr><tr><td>ABS<\/td><td>Moderate<\/td><td>High<\/td><td>Low<\/td><td>Modern and economy vehicles<\/td><\/tr><tr><td>Carbon fiber<\/td><td>High<\/td><td>High<\/td><td>Ultra-light<\/td><td>Premium or performance vehicles<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-material-recommendation-and-polishing-for-license-plates\">Material Recommendation and Polishing for License Plates<\/h3>\n\n\n\n<p>The design of license plates must meet strict engineering and legal standards, including compliance with automated traffic cameras. This includes ensuring it has nighttime visibility, readable, and durable. It must meet the standard coefficients of retroreflection (ASTM E-810) for visibility by headlights <sup><a href=\"#ref03\">[3]<\/a><\/sup>.<\/p>\n\n\n\n<p>Polycarbonate, which is 250 times stronger than glass, is the recommended automotive plastic material for harsh environments. Acrylic is often used for custom or show plates due to its high gloss and excellent color vibrancy. However, it is less durable than polycarbonate. Common surface treatments to PC automotive materials for license plates include:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong><em>Clear protective coating:<\/em><\/strong> A clear, weather-resistant topcoat that prevents yellowing or fading.<\/li>\n\n\n\n<li><strong><em>Hot stamping foils:<\/em><\/strong> Used to color embossed characters for better legibility.<\/li>\n\n\n\n<li><strong><em>UV-stable coating:<\/em><\/strong> Prevents yellowing from UV exposure.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-door-sills-automotive-material-recommendation-and-treatment\">Door Sills Automotive Material Recommendation and Treatment<\/h3>\n\n\n\n<p>They are critical horizontal components beneath a door frame. Additionally, they support structural integrity and prevent the infiltration of water and air. They are meant to withstand heavy foot traffic, too. Therefore, the ideal material is expected to have moisture and rot resistance.<\/p>\n\n\n\n<p>Composite material consisting of wood fibers and plastic is rot-proof and excellent for high-moisture areas. Powder coating is a common treatment often used to create a color-customized finish that resists fading and scratches. Texturing or grooving can also be carried out to improve safety.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-side-moldings-automotive-material-recommendation-and-treatment\">Side Moldings Automotive Material Recommendation and Treatment<\/h3>\n\n\n\n<p>Like every other external part, the material for body side moldings must resist the elements, chemicals, and impact, and must have good adhesion compatibility. ABS is the most common choice. However, Polyurethane (PU), TPO, and PP are widely used for high-impact zones, achieving excellent matte black finish, and cost-effectiveness, respectively.&nbsp;<\/p>\n\n\n\n<p>Depending on the material, treatment can include chrome plating, UV-stable painting, and clear coating. For example, ABS is usually chrome-plated to provide a high-shine luxury look.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>Vehicle type<\/th><th>Recommended material for side moldings<\/th><th>Recommended treatment<\/th><\/tr><tr><td>Luxury sedan<\/td><td>ABS<\/td><td>Triple-chrome plating<\/td><\/tr><tr><td>Economy cars<\/td><td>ABS or PP<\/td><td>Painted to match body color<\/td><\/tr><tr><td>SUV or Off-Road<\/td><td>PU\/TPO<\/td><td>Textured matte black<\/td><\/tr><tr><td>Sports or custom cars<\/td><td>Carbon fiber or ABS<\/td><td>Clear coat or painted<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-material-requirements-for-common-automotive-interior-components\"><strong>Material Requirements for Common Automotive Interior Components<\/strong><\/h2>\n\n\n\n<p>Comfort and safety are usually the primary concerns when choosing interior materials for automotive structural parts. For example, the material must comply with low-volatile compounds emissions (FMVSS 302) and be flame-retardant <sup><a href=\"#ref04\">[4]<\/a><\/sup>. They also need to have a good surface finish to improve cabin comfort.<\/p>\n\n\n\n<p>Commonly used automotive injection molding materials for interior parts include PP, ABS, PC+ABS blend, TPE, Polyvinyl Chloride, and PU. Each of these materials has its strengths and weaknesses that affect its usage.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-instrument-panels-material-recommendation-and-treatment\">Instrument Panels Material Recommendation and Treatment<\/h3>\n\n\n\n<p>Instrument panels must have high structural integrity, meet safety regulations, and be aesthetically appealing. Modern instrument panels in luxury vehicles often feature soft-touch construction. In economy variants, it is usually a hard injection-molded structure.<\/p>\n\n\n\n<p>The right material is expected to have good thermal stability, mechanical strength to support heavy components like airbags, impact absorption, and be aesthetically pleasing. The commonly used automotive plastic material for rigid panels is PP+Talc\/EPDM. It is cost-effective and offers excellent rigidity. Other material options include PC\/ABS for higher strength and long glass fiber reinforced polypropylene for rigid structural integrity.<\/p>\n\n\n\n<p>Soft-touch surfaces are usually achieved using one of the following covering materials: PVC, TPO, or PU. Plasma treatment is commonly used to make the plastic paintable or glueable. UV protective clear coat is usually applied to prevent UV degradation and fading on the top layers. Instrument panels made with PP may need an anti-static coating to reduce dust attraction.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-automotive-materials-for-door-panels-and-pillar-trims\">Automotive Materials for Door Panels and Pillar Trims<\/h3>\n\n\n\n<p>Door panel substrate or core can be made from reinforced PP because of its favorable properties, including low cost, low density, and high moldability. ABS and natural fiber composites (NFC) can also be used to achieve weight reduction. Honeycomb-based plastics are a new automotive material that is gaining attention due to their high stiffness-to-weight ratio and better acoustic properties.<\/p>\n\n\n\n<p>Pillar trims are mostly made from automotive injection molding materials, ABS, PC+ABS, and PP. Energy-absorbing structures behind the trims are usually made using polyurethane foam.<\/p>\n\n\n\n<p>Soft-touch coatings are the most common treatment applied to harder plastics to make them feel soft and improve the perceived luxury of the interior. Decorative inlays are used on pillar trims to give them a brushed aluminum or carbon fiber look.<\/p>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><th>Interior components<\/th><th>Recommended core material<\/th><th>Surface treatment<\/th><\/tr><tr><td>Door panel<\/td><td>Natural fiber+PP composite<\/td><td>Soft-touch paint, leather or fabric wrap<\/td><\/tr><tr><td>Pillar trims<\/td><td>ABS or PC+ABS<\/td><td>In-mold graining, UV coating, gloss or matte vinyl wrap<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-interior-handles-material-recommendation-and-treatment\">Interior Handles Material Recommendation and Treatment<\/h3>\n\n\n\n<p>Internal handles must balance functionality, durability, and aesthetics. It is usually made with materials that can withstand high-frequency daily use without losing their finish quality and structural integrity. ABS, PC+ABS, glass fiber reinforced PP, PMMA, and TPO are the common materials used for making interior handles. Treatment includes:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong><em>Electroplating:<\/em><\/strong> Gives a highly wear-resistant metallic, reflective finish<\/li>\n\n\n\n<li><strong><em>Painting:<\/em><\/strong> ABS or PC+ABS materials are painted to achieve a specific texture.<\/li>\n\n\n\n<li><strong><em>Coating:<\/em><\/strong> Covering the hard shell with a specialized, flexible, rubbery coat for a high-end feel.<\/li>\n\n\n\n<li><strong><em>Plasma surface treatment:<\/em><\/strong> Applied to enhance surface adhesion for printing or painting.<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-automotive-materials-for-steering-wheels-and-treatment\">Automotive Materials for Steering Wheels and Treatment<\/h3>\n\n\n\n<p>&nbsp;Modern automobiles have complex steering wheels that balance aesthetics, safety, durability, and ergonomics. The material requirements for steering wheels are strict. Ideally, it features a strong, lightweight metal skeleton surrounded by soft plastic padding and finished with a durable covering.<\/p>\n\n\n\n<p>The sub-surface automotive injection molding material is polyurethane foam. It offers a durable feel and is easily customized to specific texture, density, and color. In-mold coating is the main treatment given to PU foam to produce a uniform matte surface. It also eliminates the need for painting.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-recommended-center-console-armrest-material-and-treatment\">Recommended Center Console Armrest Material and Treatment<\/h3>\n\n\n\n<p>This automotive part bridges the gap between interior aesthetics, comfort, and ergonomics. They endure long-term physical contact. Therefore, an important property the right material must have is durability and wear resistance. They must also be resistant to oil and stains.<\/p>\n\n\n\n<p>The recommended automotive material for the structural base is ABS plastic. The padding can either be made of expanded polypropylene or memory foam to enhance pressure distribution. The outer cover is either made of PU leather or microfiber leather. For a soft premium appearance and feel.<\/p>\n\n\n\n<p>It is important to apply UV-resistant finishes if synthetic leather was used to prevent cracking or fading. Nanoceramic coatings are often applied to leather to create a hydrophobic, stain-resistant layer. This preserves the softness and allows liquids to roll off.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-material-requirements-for-common-automotive-functional-parts\">Material Requirements for Common Automotive Functional Parts<\/h2>\n\n\n\n<p>These are essential mechanical and electronic components that allow the vehicle to operate safely. Key functional, non-cosmetic parts made with automotive plastic materials include air intake manifolds, gloveboxes, and engine covers.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-recommended-air-intake-manifolds-material-and-treatment\">Recommended Air Intake Manifolds Material and Treatment<\/h3>\n\n\n\n<p>Air intake manifolds are vital engine components that distribute air or air-fuel mixtures to cylinders. Due to high operating temperatures of up to 150 \u00b0C, the right automotive material must have excellent thermal stability and high mechanical strength.<\/p>\n\n\n\n<p>Modern cars use glass fiber reinforced plastics like Polyamide 66. It brings the advantage of low thermal conductivity, lightweight, can be molded into complex runner shapes for optimal airflow, and has excellent corrosion resistance.<\/p>\n\n\n\n<p>Treatment of air intake manifolds includes polishing the runners to a smooth finish (400-1,000 grit) to increase airflow velocity. Wet manifolds retain a slight texture (400 to 600 grit) to prevent puddling of fuel on the walls. The outside is coated to enhance durability and provide heat resistance.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-automotive-material-requirement-for-gloveboxes\">Automotive Material Requirement for Gloveboxes<\/h3>\n\n\n\n<p>Gloveboxes provide safekeeping spaces for sensitive materials. The main consideration when selecting material for gloveboxes is low gas permeability and chemical resistance. The surface finish must be such that it matches the dashboard color and texture.<\/p>\n\n\n\n<p>The automotive plastic material commonly used for glovebox production is PP+EPDM. The choice is usually influenced by low cost, low density, and high moldability. Moving parts, like hinges, pivot pins, and latches, are usually made with POM. The choice is because this material has excellent wear and creep resistance.<\/p>\n\n\n\n<p>In-mold texturing is often used to create grain textures on the product. Another popular treatment is soft-touch painting of the outer door panel to reduce glare. Painting can also be used to achieve specific aesthetic requirements. Plasma treatment may be applied to the surface energy to enable proper adhesion for paints.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\" id=\"h-recommended-automotive-materials-for-engine-covers\">Recommended Automotive Materials for Engine Covers<\/h3>\n\n\n\n<p>They are either called top covers, shrouds, or engine beauty covers. They serve both aesthetic and functional purposes. Under-hood environment is extreme and requires a material that can function in such environments without deformation. The material must be compliant with safety regulations regarding flammability (e.g., SAE J369).<\/p>\n\n\n\n<p>PA66 reinforced with glass fiber is the primary automotive material used because of its excellent heat resistance and high dimensional stability. Economy or mass market vehicle models may use PP for cost efficiency. PU is often used on the back of the rigid thermoplastic cover for sound and thermal insulation.<\/p>\n\n\n\n<p>The purpose of surface treatment is either to enhance the aesthetic appeal of the engine bay or to protect the material from environmental factors. Water-based silicon-free dressings may be applied to protect or restore the \u201clike-new\u201d finish on plastic surfaces or prevent fading.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-material-differences-between-ices-and-nevs\">Material Differences Between ICEs and NEVs<\/h2>\n\n\n\n<p>Lightweighting is an important concept in New Energy Vehicles (NEVs). For example, heavy cast-iron internal combustion engines (ICEs) have been replaced in battery electric vehicles with large lithium-ion battery packs and electric motors.<\/p>\n\n\n\n<p>To increase the range that the battery packs can cover in a single charge, NEVs use extensive lightweight materials like carbon fiber, composites, and aluminum to lower the weight of the vehicles. Key material differences between Internal combustion engines (ICEs) and NEVs include:<\/p>\n\n\n\n<ol class=\"wp-block-list\">\n<li><strong><em>Powertrain:<\/em><\/strong> ICEs use steel or iron engine blocks. In contrast, EVs use electric motors and copper-heavy wiring. EVs have more compact powertrains because of fewer moving parts.<\/li>\n\n\n\n<li><strong><em>Structural material:<\/em><\/strong> To counter the weight of the battery packs, EVs usually use composites, aluminum, or magnesium alloys for the structural components.<\/li>\n\n\n\n<li><strong><em>Thermal management:<\/em><\/strong> ICEs use radiators for thermal management. EVs often use specialized plastic molded parts to build systems for air-cooling of the battery.<\/li>\n<\/ol>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-new-materials-and-development-trends-in-the-automotive-industry\">New Materials and Development Trends in the Automotive Industry<\/h2>\n\n\n\n<p>New automotive materials are emerging that will either drive the next generation of NEVs or make their operations more efficient. For example, researchers are working on the use of different hydrogen storage alloys like TiFe and LaNi to store and release hydrogen fuel to drive NEVs. Several innovative automotive plastic materials are in development that will dictate future trends in the automotive industry.<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong><em>Conductive plastics:<\/em><\/strong> It was discovered through an experimental error in the 1970s. Further studies showed that the addition of iodine during acetylene polymerization created polyacetylene that is 30 million times more conductive. This new material has been used in creating light-emitting diodes and has been valuable in sensors. It will prove useful for sensors in self-driving cars.<\/li>\n\n\n\n<li><strong><em>New polymers for industrial application:<\/em><\/strong> PHT is a new type of plastic that was accidentally developed by Jeannette Garcia. The plastic polymer is harder than bone but weighs nearly the same volume as ordinary plastic. It is 100% recyclable. It may be used in the future for the lightweighting of NEVs to improve energy efficiency.<\/li>\n\n\n\n<li><strong><em>Polytetrafluoroethylene:<\/em><\/strong> Chemist Roy Plunkett discovered this material in 1938. Scientists continue to work on developing polytetrafluoroethylene non-stick coating that can offer temperature and corrosion resistance properties. Its application as automotive seals will likely improve in the future.<\/li>\n<\/ul>\n\n\n\n<p>The combination of the desire to improve energy efficiency through lightweighting and to make the automotive industry more environmentally friendly has inspired research into new materials. More non-functional metal parts will likely continue to give way to engineered plastics.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-references\">References<\/h2>\n\n\n\n<p id=\"ref01\">[1] Ortego, A., Russo, S., Iglesias-\u00c9mbil, M., Valero, A., &amp; Magdalena, R. (2023). <em>Exergy assessment of plastic car parts<\/em>. <em>Vehicles, 5<\/em>(3), 1211\u20131226. <strong><a href=\"https:\/\/doi.org\/10.3390\/vehicles5030067\" target=\"_blank\" rel=\"noreferrer noopener\">https:\/\/doi.org\/10.3390\/vehicles5030067<\/a><\/strong><\/p>\n\n\n\n<p id=\"ref02\">[2] U.S. Environmental Protection Agency. (2024, March 14). <em>What are volatile organic compounds (VOCs)?<\/em> U.S. Environmental Protection Agency. <a href=\"https:\/\/www.epa.gov\/indoor-air-quality-iaq\/what-are-volatile-organic-compounds-vocs\" target=\"_blank\" rel=\"noreferrer noopener\"><strong>https:\/\/www.epa.gov\/indoor-air-quality-iaq\/what-are-volatile-organic-compounds-vocs<\/strong><\/a><\/p>\n\n\n\n<p id=\"ref03\">[3] ASTM International. (2020). <em>E0810-20: Standard guide for forensic paint analysis and comparison<\/em>. ASTM International. <a href=\"https:\/\/www.astm.org\/e0810-20.html\" target=\"_blank\" rel=\"noreferrer noopener\"><strong>https:\/\/www.astm.org\/e0810-20.html<\/strong><\/a><\/p>\n\n\n\n<p id=\"ref04\">[4] Aeroblaze Laboratory. (n.d.). <em>Flammability of interior materials \u2013 FMVSS 302<\/em>. Aeroblaze Laboratory. <a href=\"https:\/\/www.aeroblazelab.com\/tests\/flammability-interior-materials-fmvss-302\" target=\"_blank\" rel=\"noreferrer noopener\"><strong>https:\/\/www.aeroblazelab.com\/tests\/flammability-interior-materials-fmvss-302<\/strong><\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>\uc790\ub3d9\ucc28 \uad6c\uc870 \ubc0f \uc678\uc7a5 \ubd80\ud488\uc744 \uc704\ud55c \ud601\uc2e0\uc801\uc778 \ud50c\ub77c\uc2a4\ud2f1 \uc18c\uc7ac\uc5d0 \ub300\ud55c \uc885\ud569 \uc548\ub0b4\uc11c\ub85c, \ub2e4\uc591\ud55c \ubd80\ud488\uc758 \uc8fc\uc694 \ud2b9\uc131 \ubc0f \ud45c\uba74 \ucc98\ub9ac\uc5d0 \ub300\ud55c \uc120\ud0dd \ubc29\ubc95\uc744 \ub2e4\ub8f9\ub2c8\ub2e4.<\/p>","protected":false},"author":5,"featured_media":35507,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"categories":[48],"tags":[82],"class_list":["post-35503","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-tips","tag-materials"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v22.3 (Yoast SEO v27.5) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>Innovative Automotive Plastic Materials for Structural Parts Design<\/title>\n<meta name=\"description\" content=\"Explore automotive plastic materials for structural and exterior parts. 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