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Baydur® PUL matrix system for a lighter truck chassis 

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Commercial trucks are frequently in use, racking up mile after mile after mile. With so many trucks on the road, it’s easy to see how reducing vehicle weight can translate into a more sustainable transportation solution. By rethinking material selection, this is now all within reach. Replacing a traditional steel truck chassis with carbon fiber-reinforced composites makes it possible to cut vehicle weight and by doing so, reduce fuel consumption and CO2 emissions.  

Creating a more sustainable truck for tomorrow

Parts that are lightweight-but do not sacrifice strength-offer a number of benefits. For instance, reduced vehicle weight can positively impact commercial vehicle manufacturers by helping them meet increasingly rigorous European Union regulations. A lighter truck also enables logistics companies to transport larger loads and operate more efficiently. And, as electric mobility continues to gain traction, lightweight parts, such as the composite chassis, compensate for the battery weight and help to increase the battery range.

High productivity with continuous production

The carbon fiber-reinforced composite chassis can be produced continuously by pultrusion with a Baydur® PUL polyurethane matrix system from Covestro. The highly automated process allows manufacturers to produce sophisticated, complex parts efficiently, especially if a suitable polyurethane resin is used. The viscosity of the Baydur® PUL polyurethane matrix systems is very low but reactivity is high, which allows OEMs to produce parts very efficiently.

Fiber-reinforced chassis make trucks more light-weight and thus reduce fuel consumption.

Proving the viability of polyurethane pultrusion

Producing parts with a polyurethane matrix enables OEMs to develop thin profiles and, where possible, use less complex fiber reinforcement. A number of pultrusion runs have been successfully performed to demonstrate the system’s benefits. Of course, safety remains a top priority, and this strong yet lightweight composite chassis offers good crash performance.

With this system, we are pushing boundaries by providing a number of advantages over conventional materials: the material properties of the end part also meet stringent OEM specifications while enabling a lighter structure. Within seconds, the Baydur® PUL low-viscosity system penetrates millions of carbon fibers perfectly and enables the OEM to achieve significant productivity gains.

Benedikt Kilian

Project Manager for Process Development in the Polyurethanes, Covestro

  • Lightweight solutions enable reduced fuel consumption and CO2 emissions for OEMs.
  • Lighter commercial vehicles can now carry larger loads for increased efficiency.
  • Continuous, automated production process for complex parts.
  • Enables thinner designs.

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