Metal Replacement. Beyond metall.

In today’s automotive industry, the demand for lighter, more efficient, and sustainable solutions has accelerated the adoption of high-performance plastics to replace traditional metals. This trend is particularly significant in the e-mobility sector, where reducing vehicle weight is a critical factor for energy efficiency and sustainability.

At MPT Plastica, we have developed specific expertise to support the automotive industry in this transition. We provide advanced plastic materials that not only rival the mechanical properties of metals but also offer significant advantages in terms of cost, design flexibility, and reduced environmental impact—often eliminating the need for additional processing steps like painting.

Metal replacement is a well-established trend, but what makes it so appealing to designers and industrial decision-makers? Here are the main reasons:

1. Weight reduction: Plastic materials can weigh up to 50% less than metals, helping to reduce the overall weight of the vehicle. This is essential for enhancing the energy efficiency and range of electric vehicles.
2. Production efficiency: Plastic components can be manufactured through techniques like injection molding, enabling the creation of complex geometries in a single piece and reducing the need for multiple assemblies.
3. Corrosion resistance: High-performance plastics are resistant to corrosion and chemicals, lowering maintenance costs and improving the durability of components over time.
4. Thermal and electrical insulation: Plastics offer excellent insulation properties, making them ideal for applications where heat and energy management are essential, such as in battery systems for electric vehicles.
5. Sustainability and recyclability: Next-generation plastics, such as fiber-reinforced polymers, can be more easily recycled and contribute to lowering the overall environmental impact of production.

While the benefits of metal replacement are evident, e-mobility presents specific challenges that demand careful material selection. Electric vehicles must address issues such as battery thermal management, mechanical stress on powertrain components, and structural optimization to reduce weight without compromising safety.

MPT Plastica collaborates with leading OEMs and Tier 1 suppliers to develop plastic materials capable of:

• Withstanding high temperatures (up to 200–250°C) without deformation, thanks to materials like glass- or carbon-fiber-reinforced polyamides.
• Ensuring high dimensional stability under constant mechanical stress while maintaining lightness.
• Offering flame retardant and self-extinguishing properties to enhance the safety of electrical systems, particularly in managing high currents and voltages.

One practical example is the use of reinforced polyamides (PA6 and PA66) in structural supports that require high mechanical strength, thermal resistance, and the ability to dampen vibrations. Additionally, high-performance plastics are becoming the preferred choice for advanced cooling systems, where coolant needs to flow through complex structures not always feasible with metals.

One of MPT Plastica’s most notable metal replacement applications is the development of a license plate holder arm for a prominent motorcycle client. This complex component presented significant challenges in terms of thickness, resistance to mechanical stress, and design, replacing metallic components previously cast or machined.

Client Request: Achieve a complex component with significant thickness, resistant to mechanical stress and suitable for replacing costly metal parts.

Proposed Solution: After thorough research and material selection, PARA GF50 IXEF1025, a high-performance polymer developed by Solvay Specialty Polymers, was identified. It offers exceptional strength and rigidity, along with excellent flow characteristics even with a high glass fiber content. The innovative aspect of this project was the use of gas-assisted injection molding, an advanced technique that enabled the production of complex geometries with thin walls. This application was a breakthrough: according to Solvay Specialty Polymers, the license plate holder arm we developed is the first component globally hollowed using gas-assisted injection with PARA GF50 IXEF1025.