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Makrolon® enables lighter automotive components

As automakers seek ways to squeeze out extra weight from vehicles while maintaining stylish designs, lightweight polycarbonate materials deliver on both counts. Makrolon® is opening up completely new options for the styling and functional integration of automotive components.
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Task

Develop a lighter, yet stylish tailgate

Traditional tailgate modules are designed and manufactured with a metal carrier and glass window insert, which can add weight to the vehicle. We tasked ourselves with creating a complete, one-part tailgate with rear light modules and a display made entirely of our lightweight polycarbonate materials.
Challenge

Select a polycarbonate that is both tough and transparent

Because the tailgate would be manufactured as a one-part component, we needed to select a versatile polycarbonate that could be manufactured in a transparent grade. The material would also need to be extremely robust, given the automotive context, and suitable for injection compression molding.
Solution

Transparent, lightweight Makrolon® AG polycarbonate

We selected transparent Makrolon® AG to enable a seamless outer skin. Non-transparent areas were back-printed in a dark color or back-injected with a black frame material using two-component injection molding. The rear backlights are part of the polycarbonate skin, making assembly and logistics easier – and more economical – by eliminating the need for separate backlight and display housings. This highly integrated and distinctive tailgate offers clear weight savings over traditional tailgate designs. In the near future, Makrolon® will also help to integrate LiDAR and RADAR sensors as well as cameras into automotive exteriors.

Why Makrolon® was the right solution for our tailgate concept

  • Lightweight: Makrolon® offers high performance without weighing down applications.
  • Tough: High impact strength satisfies the requirements of automotive parts.
  • Customizable transparency: Custom and transparent grades mimic glass and other materials.
  • Highly flowable: Suitable for efficient, one-piece injection compression molding.
  • Stylish design: Glass-like surfaces in combination with hard coatings.

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Hello! Thanks for reaching out to us.
We have received your request and one of our experts will be in touch with you as soon as possible.
In the meantime, feel free to discover our innovative material solutions!

Speak to you soon,
Your Covestro Team

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