As car manufacturers continuously focus on reducing weight to improve fuel efficiency, replacing metal parts with plastic remains a key challenge. While the weight reduction can be substantial – and every 100kg weight reduction leads to a 0.3L/100km decrease in fuel consumption^[1] – it’s essential to ensure the part has sufficient strength, stiffness and fatigue resistance across the required temperature range.

We use computer-aided engineering (CAE) models to optimize the part design to ensure it meets the required performance standards. In addition to standard structural analysis, we utilize more complex tools, including anisotropic simulation and fatigue modeling with complex loading.

We have numerous examples where we supported our customers through the design phase. This ranges from predicting failure in parts that are submitted to crash loadings – such as airbag housings and structural reinforcements – to predicting fatigue failure of engine mounts at higher temperatures. 

A new addition to our portfolio is ForTii Ace, a material family that retains strength and stiffness at high temperatures, and outperforms any material in the industry. In addition to standard injection molded parts, we also support the design of parts using continuous glass fiber–reinforced tapes.

Ask us about how we can help you successfully convert your metal part to plastic, while maintaining the strength, stiffness and fatigue resistance it needs

^[1]On the Road in 2035: Reducing Transportation’s Petroleum Consumption and GHG Emissions. Massachusetts Institute of Technology (2008).