Helping you make a safer, lighter and more sustainable electric vehicle

Envalior collaborates with global automotive tiers and OEMs, leveraging decades of expertise in the automotive, electrical, and electronics industries to provide cutting-edge material solutions for electric vehicles (EVs). Our commitment to sustainability ensures that these solutions address the demands of a rapidly evolving industry.

EV charging plug with enhanced electrical safety properties required for fast-charging.

Examples of Envalior’s Advanced Materials for EVs:

• Xytron™ PPS: Designed for fuel cells, this material features low ionic leaching and high mechanical strength, improving the lifetime and efficiency of fuel cells. It’s approved by leading OEMs and Tiers in China, Japan, and Europe. With its extreme low moisture absorption PPS is an ideal material for all applications where dimensional stability is key.
• Akulon® and Durethan PA6 and PA66: A broadly used material for various lightweight structural components to increase safety in case of crash as well as a lightweight, easy-to-process alternative e.g. to replace High-Density Polyethylene (HDPE) liners, it reduces gasoline and hydrogen permeation in hybrid and fuel cell vehicles, enhancing safety and performance.
• Tepex® organo-sheets are made from glass fiber or carbon fiber fabrics embedded in a polymer matrix. In addition to providing high mechanical performance in specific applications, they offer exceptional heat resistance, helping to prevent the spread of fire during thermal runaway in batteries.
• Electro-Friendly Materials: These materials minimize electro-corrosion in critical applications like ADAS and electronic components, lowering failure rates in safety-critical systems.
• High-Voltage Insulation: As the industry shifts toward ultra-fast charging with voltages of 800V and above, our extensive material portfolio—including Pocan® PBT, PA, and ForTii® PPA compounds—features the highest Comparative Tracking Index (CTI) ratings of 600V according to IEC standards, and in some cases, over 800V when tested outside the official IEC norm. This ensures safety, reliability, and maximum design flexibility for a wide range of electrical applications.
• Advanced CTI Testing: Envalior pioneers high-voltage testing capabilities, extending beyond the IEC 60112 standard of 600V to meet next-generation requirements of up to 1500V AC and DC. Our advanced electrical test laboratories support high-voltage CTI material characterization, enabling collaboration with manufacturers to meet future fast-charging demands.

Envalior continues to lead the way in safety-focused innovation, ensuring that EV materials not only perform reliably under extreme conditions but also contribute to sustainable, efficient, and high-performing mobility systems.

Lightweighting: A core strategy for EV design

Key for EVs is lightweighting, and we have design and materials expertise making challenging structural parts, such as plastic seatings, cross car beams, front end modules or engine mounts and brackets lighter, with Durethan® and Akulon®, ForTii®, Tepex® and UDea® composites lowering total system cost. The combination of injection molding, thermoplastic composites and blow molding with various secondary processing techniques, such as welding technologies, offers the highest design flexibility for all plastic or metal/plastic hybrid structures, Tepex organo-sheets can be directly processed via hybrid molding on standard injection molding equipment in mass production.

For composite designs our UDea unidirectional tapes and Tepex woven structures are used by many global automakers because they offer in average about 50% weight reduction vs. incumbent metal solutions, a shorter production time and high functional integration such as e.g. used in the FRP center tunnel of Porsche 718 Boxster/Cayman or our Tepex composites in combination with PA6 used in new designs for battery enclosures.

Full plastic battery enclosure realized together with Kautex.

Also, to make lighter and safer gears and actuation systems, Stanyl® PA46 offers higher torque and durability than alternative thermoplastics such as PPO, PPA or PA66. For EV electric brake boosters and parking brakes, a smaller and lighter design is needed. Stanyl® is a proven solution that is already used more than 100 million automotive gears each year.

Driving sustainability forward with innovative materials and transparent solutions

Recently we announced to cut our scope 1 + 2 greenhouse gas emissions 100% by 2040 and 75% by 2030 based on a 2016 baseline, to use 100% renewable electricity by 2030 in all sites, have the carbon footprint of our main products in the top quartile of the industry and to offer our entire portfolio in bio- and/or recycled-based alternatives by 2030. Specific grades are already available for all major Envalior product lines (with at least 25% bio and/or recycled based content in the final product).

For example, with its bio-based alternative materials solutions, EcoPaXX® PA410 & Arnitel® Eco TPE, we can support CO2 reduction for increased OEM sustainability requirements today without design changes or requalification. Also, Akulon® RePurposed PA6—a post-consumer recycled PA6 alternative to fossil-fuel-based plastics made from used fishing nets recovered from the Indian Ocean and Arabian Sea—offers like-new performance. Besides various existing PBT compounds with recycled glass fibers, we are proud for having recently launched a new range of sustainable Pocan PBT compounds based on bio circular BDO derived from used cooking oil. These PBT compounds have a sustainable content of 26%. This portion can be further boosted if e.g. PET from post-consumer recyclates and recycled glass fibers are used additionally to the sustainable BDO. Our newly launched Pocan T3230 RC-X-MB contains a total sustainable share of around 71 percent. In addition, Tepex woven fabrics are also available based on flax fibers and bio-based polymers like PLA (Poly Lactic Acid) and PA10.10.

SPE Automotive innovation award-winning wire-harness clips for Ford Bronco Sport made of ocean plastics.

Most important to our customers is that we enable value chain transparency by providing the carbon footprint data of all main grades, based on supplier input and regional validation. The data is available to all relevant customers in our downstream value chain.

At the core of our strategy is Safer, Lighter and more Sustainable EVs, and we will continue to invest in the further development of existing and new applications, in close cooperation with partners from across the value chain.

Contact us to learn more about our materials solutions for EV applications.