Dow advancement strengthens, diversifies TPO use in autos

When it comes to lightweighting, Dow Inc. isn't pulling any punches.

The Midland, Mich.-based company's Engage 11000 thermoplastic polyolefin elastomers are stretching the capabilities and applications of TPOs, offering auto makers and suppliers more versatile materials for vehicle design and function, particularly in the area of lightweighting.

But don't just take the company's word for it.

Dow's advancements with its Engage technology earned it one of R&D World Magazine's prestigious R&D 100 Awards, making it one of five Dow technologies to garner the accolades this year.

For Mark Jablonka, Dow's transportation application technology leader, it was affirmation that he and his team are pushing innovation further and offering OEMs and suppliers more diverse capabilities.

"The R&D 100 Award and the development of the novel elastomer is something that I am really proud of," Jablonka said. "This is a great achievement for Dow."

Engage polyolefin elastomers create tougher, more durable TPOs, while reducing the coefficient of linear thermal expansion, Jablonka said. As a result, application of the material is extended, particularly to the body of the vehicle.

In terms of functionality, the ability to replace traditionally heavy metal body panels with much more lightweight TPO panels allows for more fuel-efficient vehicles. And as the industry transitions to electrification, that weight loss becomes more important, offsetting the weight of the heavy battery packs and extending the vehicle's range.

Jablonka also noted that the molding versatility of TPOs make them an ideal material for auto makers because they eliminate the need to weld brackets and fixture attachments, which are common with steel and metal parts. This saves on weight, time and money, Jablonka said.

"Part integration is a key area that reduces cost, and it reduces assembly time," Jablonka said. "You are using less material to make the same part. That is weight savings, and it equates to parts savings as well."

And that's where Dow's advancements with Engage make a difference. Because the TPO's CLTE is reduced with the use of Dow's novel elastomer, the material isn't prone to significant expansion when heated. It reacts more like a metal in this regard, reducing gaps between the plastic body panels to creating cleaner, more uniform looks that customers often associate with quality.

"From a panel look standpoint, they will look the same as metal; you won't see a big difference there," Jablonka said. "Where you will see a difference is if the designer goes beyond what they would typically be constrained with. You can put a lot more styling and design features into a TPO panel."

Most often, these design details take shape in the vehicle's internal components, such as cockpit panels. But that could change, especially as electric vehicle battery placements allow designers to stretch their creativity.

"It opens up more freedom to change the look of the car," Jablonka said. "That is where TPO is going to be very much welcomed, by designers at OEMs who have been constrained by what they can do with metal. These futuristic looks and design features that are different, it will give brands the opportunity to put things into their designs that weren't possible before because they can shape it any way they want."

Moreover, Jablonka said, transitioning to the plastic body panels won't come at the cost of durability because Dow's Engage 11000 polyolefin elastomers can toughen TPOs.

"The other advantage is the dent and ding resistance," Jablonka said, noting that danger lurks in every parking lot and driveway in the form of shopping carts, kids toys and fellow drivers. "This TPO can really help make your vehicle look newer longer."