Best in Automotive Innovation: Sustainability

The final installment of our series of articles showcasing the finalists for the Society of Plastics Engineers (SPE) 52^nd annual Automotive Innovation Awards introduces the nominees in the sustainability category. The winners in all categories will be revealed during the SPE Automotive Innovation Awards gala on Nov. 8.

Basalt fiber-reinforced ADAS bracket

By replacing E-glass with basalt fiber in this injection molded ADAS bracket, which also contained 60% post-industrial recyclate (PIR) PA 6, cost and weight were neutral, the part met all performance requirements, and no tooling changes were needed. A 74% CO₂ reduction was achieved and 180,000 kg of material annually is kept from landfill. The drop-in change is more sustainable, addresses glass-shortage issues, and provides the same performance as virgin material.

Bracket from recycled BMC

Replacing magnesium with unsaturated polyester BMC yielded structural brackets meeting high dimensional requirements at comparable or improved mechanical performance, especially in terms of toughness. The bracket was made more sustainable with inclusion of 6% PIR acrylic resin (PMMA) and 5% PIR BMC scrap, which replaced calcium carbonate filler. It took two years of work to develop the process to recover and reclaim thermoset BMC scrap and reuse it in new parts with a lower CO₂ footprint. Key to the success of the program were grinding, sizing, and formulation strategies. No tooling changes were required to replace the virgin BMC.

One-piece frunk

This is the first time a 20% PCR material has been used in a color-matched, molded-in color (MIC), Class A structural frunk application. Compared with virgin TPO, the more-sustainable grade lowered density slightly and offered better impact at -15°C. Concurrent redesign reduced component count from six to one. The elimination of two metal brackets saved 3 kg of mass, increased cargo volume and functionality, improved water management, reduced cost and labor, and saves an estimated 1,125 tonnes of CO₂ annually. PCR content is sourced from yogurt cups and packaging materials.

Eco-friendly cable control 

This is the first broad-scale shift from virgin to post-industrial recyclate (PIR) PA 66 in cable management parts, a drop-in-change offering comparable performance, aesthetics, and processing at lower cost and a 35% lower carbon footprint without any part design or tooling changes. Although the parts are small, they are produced in high-cavitation injection tooling and offer best-in-class mechanical, thermal, and chemical performance. In just the first year, the change reduced CO₂ emissions by 138,000 kg and saved 70,000 kg of coal.