The advantages of plastic within the automotive industry

Over recent years, the automotive industry has significantly increased its use of plastics. It already relies heavily on them for many key vehicle components. What’s more, it’s expected that the automotive industry will make even greater use of plastics in the future.

Here, Ansini share their guide to how the automotive industry benefits from using plastics. 

History of plastics in the automotive industry 

Plastics have been used in the automotive industry for many decades and in the 1950s their use began to increase significantly. Early applications of plastics in cars included the use of Bakelite, a type of plastic developed in 1907, for gear shift knobs and steering wheels. Plastics were also used for electrical components and interior trim. 

The 1970s and 1980s saw a surge in the utilisation of plastics in automobiles. This was mainly due to the oil crisis and a desire to enhance fuel efficiency. As a result, there was the invention of plastic body panels and lightweight plastic components like bumpers.  

Car manufacturers also saw the potential of plastics as a cost-effective alternative to traditional materials like metal and glass. The flexibility of plastics enabled the creation of unique designs that would appeal to consumers. Additionally, plastics provided increased design flexibility and allowed for the creation of parts with a high level of detail. 

Today, plastics continue to play a significant role in the automotive industry. Automotive parts manufacturers are using advanced plastics, such as composites and thermoplastics, to create lighter, more durable, and safer vehicles. Plastics are being used in many new applications, such as LED lighting, battery cases for electric cars and interior components. 

Advantages of using plastics within the automotive industry 

Plastics is a broad term that encompasses various materials with distinct properties. Taken as a group of materials, however, plastics offer advantages that cannot be matched by other materials. 

Cost-effectiveness in manufacturing 

When compared to conventional materials like metal and glass, plastics tend to have lower production and manufacturing costs. This is attributed to the reduced cost of raw materials and the convenience of moulding and shaping plastics into particular shapes and sizes. 

In addition to the lower material cost, plastics also offer cost savings in the manufacturing process. They can be produced through various moulding techniques, including injection moulding, blow moulding and compression moulding, which are highly automated and require fewer workers. These techniques also result in less waste material and lower scrap rates, further reducing manufacturing costs. 

Plastics provide an increased level of design flexibility, allowing for effortless customization to meet specific requirements. This means that car manufacturers can produce unique designs for car parts that are both functional and visually appealing, without incurring the extra costs associated with more conventional materials. 

Flexibility and versatility 

The flexibility of plastics enables automotive manufacturers to create car parts with unique shapes and features that can not be cost-effectively created with traditional materials such as metal and glass.  

In some cases, plastic components can make vehicles more aerodynamic. This makes them pleasanter to handle and also more fuel/power efficient. Moreover, plastics are much lighter than traditional materials. This helps to improve fuel/power efficiency. 

The flexibility of plastics also makes them ideal for producing parts that require a high level of resilience and durability. For example, plastics can be used to create shock absorbers, seatbelts, and airbag components. These all require materials that can withstand extreme forces and impacts. 

Durability and resistance to corrosion and chemicals 

Plastics are highly resistant to both corrosion and UV rays, as well as withstanding extreme temperatures, both high and low. These qualities make plastics an ideal choice for manufacturing car parts that are regularly exposed to the elements. Plastics can also be useful for creating internal components, such as engine covers, insulation, and electrical components, that require durability and resistance to extreme temperatures. 

The fact that plastics have a high resistance to many chemicals, including oils, fuels, and cleaning agents, makes them an excellent option for manufacturing car parts such as fuel tanks, engine components and electrical connectors. 

Moreover, plastics have high durability and offer an excellent strength-to-weight ratio. This enables them to withstand high levels of impact and vibrations. As a result, plastics are highly useful in the manufacturing of car parts such as bumpers and door panels. 

Enhanced safety features 

Plastics also play a crucial role in enhancing safety features in automobiles. For instance, airbags and seat belts are vital safety components in a car that rely on plastics. Plastic parts, such as the airbag housing, are designed to deploy quickly and effectively in the event of a collision, thereby reducing the risk of injury to the driver and passengers. 

Additionally, plastics can be engineered to have certain mechanical properties that enhance safety features. For example, certain plastics can be made to be more impact-resistant than others, making them an ideal choice for creating safety features such as bumpers, side-impact beams, and crush zones. 

Furthermore, the use of plastics in manufacturing car parts can help to reduce the overall weight of the vehicle. This can, in turn, increase fuel efficiency and reduce emissions, making it an environmentally friendly option. 

Lightweight materials and improved fuel efficiency 

Substituting plastic parts for metal ones can reduce the weight of vehicles without compromising on strength, safety, or durability. The use of lightweight materials like plastics can lead to a significant increase in fuel/power efficiency, ultimately reducing a vehicle's carbon footprint. 

Lightweight plastic components such as fuel tanks, engine covers, and door panels can lead to reduced fuel consumption by decreasing the weight of the vehicle. This can, in turn, result in lower carbon dioxide emissions and improved environmental sustainability. Additionally, lightweight plastic parts can improve vehicle performance by reducing the overall mass, which leads to a more responsive and agile driving experience. 

Future of plastics in the automotive industry 

The future of plastics in the automotive industry is likely to be shaped by ongoing developments in materials and manufacturing technologies. Car manufacturers are increasingly focused on sustainability and reducing the environmental impact of their products, which is likely to drive the development of new, more eco-friendly materials. 

In recent years, there has been a growing trend towards the use of bioplastics, which are derived from renewable sources and are biodegradable. These materials have the potential to reduce the environmental impact of plastics in the automotive industry and could play a significant role in future car manufacturing. 

With all that said, there are also challenges associated with plastic use and disposal. Plastics are a major source of pollution, and the disposal of plastic waste is a significant environmental issue. Car manufacturers will need to find ways to reduce the amount of plastic waste generated during production and ensure that materials are recycled or disposed of responsibly.