Plastics bring solutions in auto lighting, exteriors for autonomous cars

The automotive industry needs new concepts to meet optical and physical requirements for exterior parts, as signaling and communication become important aspects for a move toward automated driving.

Auto suppliers Marelli and Samvardhana Motherson Automotive Systems Group have formed a new partnership to integrate sensors for advanced driver-assistance systems and autonomous driving in illuminated exterior body parts like front grilles, bumpers and others.

The partnership plans to create translucent, back-lit trim parts and other decorative panels, with LED lighting shining through them at night and taking on the color of the car body in daylight, both partners told Plastics News in a joint statement.

"Parts like front or rear ends, fenders and rocker panels will evolve into smart illuminated body panels that will give vehicles an even stronger brand signature," the joint statement said. "Smart illumination opens new possibilities for OEMs to support diversification of brands and models, also with possible different day and night styles.

"It is becoming more and more important for the authorities to set rules on how to make fully automated cars recognizable," the statement said. "Future illuminated parts offer new openings for this purpose and can be used for communication as well."

While the companies work together to develop parts like bumper fascias, which aren't commonly translucent, out of optical materials, they will also have to meet safety requirements and integrate sensors, like LiDARs, radars and cameras, as autonomous driving systems become required features.

Marelli and Motherson jointly declined to comment on "any specific materials used for certain application" amid the project.

The companies have already started working with several customers, helping OEMs develop parts with specific styling and functional purposes, like different day and night features "within one model range they can distinguish one version from the other," the joint statement said.

"The end use and function of the part is decisive when choosing material or defining the process," it added. "We see the combination of the optical and decorative material technologies and the smart processing of existing ingredients as very promising in the future."

Motherson uses injection molding, films, printing technologies and painting and surface coating to integrate light modules into large exterior parts like bumpers and fascias, Timo Schwarz, chief technology officer at Motherson Innovations, told Plastics News.

"The integration of the light sources within the exterior parts is the key for a successful product," Schwarz said. "Marelli's strong knowledge of the legal requirements for lighting systems brings additional expertise to the partnership. … The very human, mutual understanding between both businesses make this a strong partnership."

Within the partnership, Marelli's lighting division will focus on automotive lighting and sensors integration, a July 28 news release said.

Marelli applied a similar concept in its Smart Corner product, which integrates sensors for autonomous driving within vehicle headlamps and tail lamps, Andrea Stella, senior vice president of research and development at Marelli Automotive Lighting, told Plastics News.

The illuminated body panels, which include displays, headlights and rear lights or other parts, "rely on sophisticated electronics and depend on networking with the car architecture," Stella said.

"The successful interaction of all elements is the key to communication within the car system where electronics command the cameras and the sensors and is also crucial to enable vehicle-to-vehicle and vehicle-to-everything communication," she said, "creating a connected system between the car, the driver and the surrounding environment.

"Marelli and Motherson have a long-lasting and very successful partnership over many years, having established a joint venture in 2008 to address the India exterior lighting market," Stella said. "Our know-how in products and technologies complement one another and eased the fusion of body panels and exterior lighting.

"Our very similar customer portfolio allows us to remain a partner of choice for our customers," she added. "It's always the satisfying full package that makes you choose the one possible partner rather than the others."

The companies' joint statement notes that they aim to play a crucial part in upcoming technological and sustainable developments in lighting and plastics.

"Driving innovation and shaping the future of mobility together with our customers requires not only the ability to best respond to their current needs, but most of all the ability to anticipate forthcoming evolutions and rising market trends," Sylvain Dubois, CEO of Marelli's Automotive Lighting division, said in the release.

"We are sure that this new collaboration will be a solid step towards achieving new strategic developments in the evolution of the automotive market," Dubois said.

Marelli Automotive Lighting is a division of Marelli that designs external automotive lighting systems and sensors for autonomous driving systems. SMRP BV (Motherson) develops and manufactures polymer modules, including cockpits, door panels, front and rear bumper modules and more for the automotive industry.

Marelli's strong knowledge of the legal requirements for lighting systems brings additional expertise to the partnership. … The very human, mutual understanding between both businesses make this a strong partnership."