Roof Sensor Module for self-driving cars

As a leading polymer company, we supported Webasto with polycarbonate expertise and processing know-how during the development of the RSM cover. The cover must meet stringent mechanical requirements while offering an aesthetic exterior design with   sensor transparent windows. Additionally, it had to provide the necessary design freedom for embedding electronic components and fixation elements.

The primary challenge was to develop a cover that could seamlessly integrate multiple sensors while maintaining optimal performance and durability. The cover had to be highly permeable to sensor signals, such as those from LiDARs and cameras, while also offering thermal management capabilities to prevent overheating and ensure reliable sensor operation. Furthermore, the cover needed to be resistant to adverse weather conditions, ensuring flawless operation, e.g., in extreme high or low temperatures.

Our solution involves a two-component injection compression molding process. The first shot is made from the transparent polycarbonate Makrolon® AG, which is highly permeable to various sensor signals.

For the second shot, the black, mineral-filled PC-ABS Bayblend® T95 MF is being used. Thanks to the combination of both materials, the roof module meets high mechanical requirements and at the same time offers an attractive glass-like exterior design and sensor transparency.  The high heat resistance of polycarbonate ensures that the cover retains its shape even in high temperatures, without impairing sensor function. 
 
A colored Makrofol® ST film brings decoration and function in while maintaining excellent LiDAR, NIR signal permeability.