Lightweighting solutions for automotive components

On June 12 and 13 DuPont showed its latest innovations to the international press at its Innovation Centre in Geneva. They will be introduced during the next edition of the K show in Dϋsseldorf (October 16-23).
Innovative technology and material solutions to automotive lightweighting - helping automakers take weight out of vehicles to reduce emissions and improve fuel economy - are currently top of DuPont Performance Polymers R&D agenda.
The policy embraces collaborative developments with the industry to help get innovation into the market faster. Latest examples include a truck oil pan of DuPont Zytel polyamide resin up to 6 kg (50%) lighter than the aluminium it replaces, and a developmental thermoplastic composite technology that shows a 40% weight reduction compared to ultra-high strength (UHHS) steel, while absorbing more energy than metal and short glass-fibre polymer beams. As a result, DuPont Vizilon passed PSA Peugeot Citroën's crash test, making it well suited for crash components. It also offers stiffness performance in temperatures from -40° C to +90° C, and outperforms polypropylene-based composites above 80° C.
"The auto industry is facing many difficult challenges, the most critical in Europe being carbon dioxide emissions reduction. Coupled with more aggressive engine coolants and temperatures, and the added weight of new performance, comfort and safety features, these challenges are creating major lightweighting opportunities for DuPont's engineering polymers and high performance elastomers," explained Patrick Cazuc, automotive director EMEA, Dupont Performance Polymers, and also added: "Light thermoplastic composites offering enhanced stiffness, and adoption of new oil pans, exhaust mufflers and tailpipes in DuPont plastics, are prime examples. We are collaborating with automakers to get these innovative ideas into the market faster with greater reliability, and at affordable cost."
Furthermore DuPont is focused on reducing dependence on fossil fuels, with investments in advanced materials and expert application development, especially in lighter weight alternatives to metals that can withstand the intense heat, aggressive chemicals and constant high pressures in modern automotive engines.
Much of the developmental work is carried out at the Innovation Centre in Geneva, one of the eleven DuPont's Innovation Centres worldwide, connecting customers, strategic partners and academics with more than 10,000 DuPont scientists and engineers. Four of these centres are focused on the automotive industry, where the company's global development teams work on five innovative pathways to lightweighting, engine efficiency, bio-based solutions, electrification and alternative drive systems.