Ticona Engineering Polymers (Sulzbach, Germany) and Swiss auto developer Rinspeed Inc. (Zumikon) have deployed a number of plastic technologies in an electric concept vehicle to reduce weight and achieve the greatest possible design freedom. The BamBoo utilizes Celstran continuous fiber unidirectional thermoplastic composite tape (CFR-TP), MetaLX metal effect polymer and Hostaform acetal copolymer (POM).

Celstran CFR-TP PP GF70 is a 20-mm-wide, 70-percent glass polypropylene continuous fiber tape that was used for the underbody and wheel wells. Specifically, two layers of the fabric are pressed to create a 1-millimeter underbody wall thickness, while three layers are used in the wheel wells to achieve greater stiffness. Ticona worked with Oxeon (Borås, Sweden during the manufacturing of the tape, and Kringlan Composites (Otelfingen, Switzerland manufactured the concept components.

Celstran CFR-TP POM GF60 is a 60-percent glass Hostaform POM continuous fiber tape, also produced by Oxeon, that was used to mold homogeneous and smooth interior applications such as the instrument panel covers and door sills.

Furthermore, Celstran CFR-TP PPS CF60, a 60-percent carbon fiber Fortron polyphenylene sulfide (PPS) tape wound without an inner core by Advanced Fibre Placement Technology (AFPT; Sprang-Capelle, The Netherlands) was used for the tailgate and roll bar. The structural roll bar is constructed from the Celstran CFR-TP using a cross-winding process that ensures particularly high stiffness. A comparable roll bar constructed of aluminum or steel would have increased the weight of the BamBoo by 20 percent or 50 percent, respectively. The roll bar is integrated directly in the vehicle structure to connect the cockpit with the vehicle substructure adding stability to the BamBoo.

In addition, Hostaform MetaLX POM adds shine to the metal inserts of the three-spoke steering wheel. Further, a new-impact modified version adds strength and joint line integrity to a roof pole. The MetaLX metal-effect polymer, an appearance-focused engineering thermoplastic from Ticona, can reduce costs and eliminate chemical pollutants associated with painting and, at the same time, achieve the aesthetics of a metallic look. Hostaform POM is also used in various parts of the concept car, including the interior blinds that feature painted visual highlight drawings by the New York artist James Rizzi.-[email protected]