Althoff

China is in the middle of an attractive automotive boom. The China Association of Automobiles has predicted China will sell more than 11 million vehicles by the end of the year. The numbers might be high, but most domestic manufacturers still lag in the use of engineering plastics.

"We see in China a huge potential and not only because the auto industry is growing," said Hermann Althoff, group vice president of BASF Engineering Plastics Asia Pacific. "There is the potential to increase (engineering plastics) by more than five-fold."

Engineering plastics help to lighten the overall weight of a car, offering increased energy efficiency and saved money on gas. Programs like Ultrasim also help speed up the design and production of certain parts, helping to cut down on production costs. The simulations also expand the scope of applications for engineering plastics. "Simulations make it possible to design engineering plastics that were formerly confined exclusively to metals," Althoff said.

The program relies on a comprehensive data set that describes the properties of BASF’s engineering plastics. It takes into account how glass fibers, which are used to reinforce engineering plastics, influence the part during mold filling. The program simulates high-stress situations and car crashes to model how the part will react. It also considers how a product will react over time.

“Today’s vehicles need to perform in harsh environments, from extreme heat and cold to rocky terrain and mud,” said Althoff. “Engineering plastics need to be durable enough to function efficiently and reliably in these adverse conditions.”

Ultrasim, however, does have some limitations. Because the program relies on a set of data pertaining to BASF’s own materials, the program is not effective for use with other materials. Engineering plastics, also, can be more expensive to produce than their metal counterparts. “Lightweight cars can be more costly,” Althoff admitted. But, he added, there are ways to bring down price, such as integrating several functions into one engineering plastics part.

While China currently uses less plastic in the manufacture of automobiles, Althoff sees growing interest in new materials. “Automobile makers are becoming increasingly sophisticated,” he said. “The development was the same in the U.S. and Europe – the more sophisticated, the more engineering plastics.”