Magna plastic exterior components offer advantages for EVs

Detroit — Magna International Inc.'s new electric vehicle exterior technologies feature plastic components to integrate advanced driving (ADAS) systems, lighting designs and aerodynamic functions that can improve vehicle range.

The supplier's new Mezzo Panel is compression injection molded, giving it a "traditional depth, like an open-air grille for an internal combustion engine," Mark Hess, global product technical manager at Magna, told Plastics News at the North American International Auto Show in Detroit.

Compression injection molding allows Magna "to get the depth changes in the wall stock," Hess said, giving it the appearance of a traditional grille, while maintaining a smooth front that is lightweight and aerodynamic "by being one piece vs. layered pieces."

Traditional automotive brands "want to keep their branding moving into the EV space," he said.

The Mezzo Panel features "hidden-until-lit lighting," meaning the surface looks smooth until lighting is activated, allowing for animated lighting options for brand distinction or communicating vehicle intent.

"Some of the more traditional OEMs like the light-off brand recognition," Hess said.

Compression injection molding allows the manufacturer to add metal deposition, paint or in-mold film for visible branding and decorations that add a "level of distinction without a big tooling change for the OEMs," he said.

Future iterations of the Mezzo Panel might feature sustainable materials, like post-consumer recycled plastics, coatings and films, that would meet demand for sustainability goals for OEMs, Magna says. Those materials would feature the same properties that allow for transmission of autonomous driving signals and integration of ADAS sensors.

Magna is working to develop post-consumer recycled materials for exterior components, Parvinder Walia, director of material science at Magna, told PN.

Recycler UBQ Materials processes household trash to supply Magna with recycled content that can be blended into materials for exterior parts.

A part with 5 percent recycled material, Magna's current goal, is about a 30 percent carbon footprint reduction, Walia said. "The goal is obviously to put in as much as we can to try to [decrease] the carbon footprint and essentially divert material going to landfills."

Magna plans to launch recycled materials in exterior parts soon, he said. The company currently only uses PCR materials in hidden components.

Through a joint venture with Rohinni Inc., an Idaho company developing micro and mini LED applications, Magna is developing FlecsForm, thin-film micro and mini LEDS on a flexible material that is "as thin as a piece of paper," Magna's website said.

The LEDs also offer improved power and thermal efficiency.

Magna showcased the technology in a thermoplastic lift gate with "breakthrough lighting" that could shine through the plastic component at the Detroit auto show.

"Plastics are very light and sensor-friendly," Rob Selle, global product technical director at Magna, said at the show.

Magna's tailgate uses a tinted, compression injection molded polycarbonate panel, without painting or film, Selle said.

The LED's light transmission meets regulatory performance standards for braking by shining through a translucent thermoplastic polyolefin material.

The company used a "special paint process" that allowed Magna to transmit light through "micro holes" in the TPO, Selle said.

Using standard light modules, OEMs won't need to "tool up for a unique tail lamp," he said. "It's all common across the board."

LEDs are able to shine "out to the edges" of the tailgate, something Magna's customers "have a lot of interest for," Selle said.

Other exterior applications for the technology include daytime running lamps, exterior mirror signals, appliqués, truck bed lights and license plate trim, among others.