ELIX Polymers has introduced a new generation acrylonitrile-butadiene-styrene/polycarbonate (ABS/PC( blend to meet the needs of the automotive industry. ELIX Ultra HH 4115 HI ABS/PC can reportedly help to achieve major weight reductions through lower density, as well as delivering cost savings, processing benefits, very low emissions and odour when compared to PC/ABS.

The automotive industry’s ongoing search for weight reductions, is currently driving the trend to replace PC/ABS parts with ABS/PC blends, especially for interior parts. The new generation ELIX Polymers Ultra HH4115HI ABS/PC material reportedly boasts several advantages compared to a PC/ABS: 5% lower density with 1.07 g/cm³ vs PC/ABS 1.13 g/cm³, low emission and odor (VDA 278 VOC = 8 / FOG = 3 μg/g (ppm), VDA 270 = 3.0). Its high flowability rate (MVR = 14 cm³/10min.) helps to reduce cycle times, so that more parts per hour can be produced. Other benefits include its very high impact strength (ISO180-1A = 58 KJ/m² at 23°C room temperature and ISO180-1A = 41 KJ/m² at -30°C), excellent processability and very good paintability. Furthermore, there are significant cost saving possibilities thanks to the better painting performance and reduced scrap rate of Ultra HH 4115 HI vs PC/ABS.

Tests according to ISO6603-2 (puncture impact behavior) also show good performance of Ultra HH 4115 HI at different temperatures for crash-relevant parts such as interior pillars. The appearance of fracture has been evaluated as very positive by several premium car manufacturers.

ELIX Ultra HH 4115HI has already been tested and approved by several leading automotive OEMs. BMW approved it according to GS93016 ABS+PC heat resistance standard and the first serial projects are already running with the new grade.

Further, Audi tested emissions and odor parameters with positive results and the material is considered as very interesting for lower instrument panel parts, center console parts and door panel parts according to TL52231.

In addition, GM recently approved UltraHH4115HI under its GMW15572-T4 standard. Further tests and approvals at other OEMs are running at the moment, and Tier suppliers have shown interest in this new ABS/PC grade.

Target applications for the new  material include door panel parts, instrument panel parts, center console trim, seating parts, interior and exterior pillars, and luggage compartment trim. As with other grades of ELIX Polymers, pre-colored material in OEM colours is possible as are tailor-made solutions with special additive packages for very demanding part requirements.