The latest commercial example of a plastic fuel sump to be announced comes once again from DSM. The company's Akulon Ultraflow polyamide (PA) 6 resin has been employed in the injection molded oil sump used in the new Mercedes-Benz S Class. The sump joins a cluster of European-based developments over the last several years. Click here and here for more examples.

Needless to say, the oil sump weighs less than a metal version but it also costs less to produce. The sump developed by German Tier One supplier BBP (Marbach am Neckar, Germany) for Mercedes-Benz is around 50% lighter than the metal version it replaces. The two companies subjected it to some very demanding application tests, including vibration, stone impact, and an engine drop test. Oil sumps provide a considerable challenge for developers: their exposed position under the engine means they have to be very resistant to impacts and mechanical stress.

The grade used for the PA 6 with high resistance to engine oil, and very good flow properties. Its significant processing advantages come at no cost to mechanical properties compared to standard PA 6 products.

Horst Hauke, Director Sales Automotive at BBP, says: "With materials like Akulon Ultraflow, we can make important progress in demanding engine compartment applications to reduce fuel consumption and carbon dioxide emissions. The oil sump is an important breakthrough, and it demonstrates that DSM is listening to its partners along the supply chain in its development of materials to address the performance and sustainability challenges that we all face."