PIAE EUROPE 2025

Produktbeschreibung

Contents

Circular Economy/Kreislaufwirtschaft
Future Sustainable Car Materials – A Contribution to a Sustainable Circular Economy for Plastics in Automotive Engineering 1

Future Sustainable Car Materials – ein Beitrag zu einer nachhaltigen Kreislaufwirtschaft für Kunststoffe im Automobilbau 11

Post-consumer recyclates from end-of-life-vehicles 23

Manufacturing Processes 1/Fertigungsverfahren 1
Challenges and limitations of high-quality PCR regrinds in the interior and exterior according to the costly regulations of the ELV 39

Herausforderungen und Grenzen von hochwertigen PCR Regranulaten im In- und Exterieur nach den expensiven Regularien der ELV 49

TPE compound utilizing core-back foam injection molding for automotive interior parts process simplification and recyclability improvement 59

Expanded polypropylene beads done by foam extrusion for automotive applications – Revolutionizing the ePP market in automotive applications 67

Interior/Interieur
Vehicle interiors from the perspective of sustainability – Alternative trim materials under discussion 77

TPE safety glass?! – An automotive application in the field of exterior trims 93

Sicherheitsglas durch TPE?! – Eine automobile Anwendung im Bereich der Exterieurblenden 101

Automation – a pillar of the sustainable, high-quality interior 109

Automatisierung – Eine Säule des nachhaltigen, wertigen Innenraums 123

Exterior/Exterieur
Porsche adaptive front diffuser – from racetrack to street 139

Porsche Adaptiver Front Diffusor – Von der Rennstrecke auf die Straße 157

Recyclate use and passive safety: components in the bumper of the new Audi A5 175

Rezyklateinsatz und passive Sicherheit: Bauteile im Stoßfänger des neuen Audi A5 193

Lightweight Design 1/Leichtbau 1
Process combinations for the production of sustainable load-appropriate molded parts 209

Prozesskombinationen zur Herstellung nachhaltiger belastungsgerechter Formteile 219

Method development for mapping the mold-filling process of thermoplastic compression-molded components with continuous-fiber reinforcement and complex rib structure 229

Methodenentwicklung zur Abbildung des Formfüllprozesses thermoplastischer Pressbauteile mit Endlosfaserverstärkung und komplexer Rippenstruktur 239

Plastics Electronics/Kunststoffelektronik
Innovative EMI-Shielding plastics – Functional integration enabling weight and cost reduction in the example of a DC-DC converter application 249

From ideation to validation – Low-pressure overmolding in ADAS cameras 261

Sustainability 1/Nachhaltigkeit 1
Uncovering the Material State: Potential of PA66 Fan Modules from End-of-Life Vehicles for Closed Loop Recycling 271

Lignin – Next generation renewable resource for sustainable plastics BioForm project, bio-based and sustainable materials with vacuum forming for the automotive industry 287

Simulation
Enabling Reliable Virtual Prototyping with Digital Material Twins – The current state of the art from the perspective of a plastics manufacturer 301

Competitive Advantages Through Smart AI-Driven Engineering 311

Wettbewerbsvorteile durch smartes KI-gestütztes Engineering 323

Lightweight Design 2/Leichtbau 2
Sustainable Innovation – Achieving Net Zero with Function-Oriented Plastic Design, Tool Design, and Process Management 337

Ultrasound based measurement of mechanical properties of continuous fiber reinforced thermoplastic laminates – A non-destructive method to identify changes in fiber matrix adhesion 347

Recyclates/Rezyklate
A contribution to sustainable development – the use of recyclates in highly loaded applications 361

Risk potential use of post-consumer recyclates – PCR What the automotive industry can learn from the food and hygiene products industry 373

Risikopotential Einsatz von Post-Consumer Rezyklaten – PCR
Was die Automobil-Industrie von der Lebensmittel- und Hygieneartikelbranche lernen kann 383

Reliable component quality despite PCR recycled materials 395

Materials/Werkstoffe
Tier 1 Supplier Role in Boosting PCR Integration in Automotive Injection-Molded Products for a Circular Economy 405

Sustainability and Circular Economy – Applying new sustainable materials into plastic parts 407

Expanded TPE – more than just a gap filler 419

Expandiertes TPE – mehr als nur ein Lückenfüller 421

Manufacturing Processes 2/Fertigungsverfahren 2
BIOPOLYMER PBS – The foreseeable future of plastics: from vision to concrete applications 423
BIOPOLYMER PBS – Die absehbare Zukunft der Kunststoffe: Von der Vision zur konkreten Anwendung 431

TPE as a recyclable alternative for sealings and haptic parts 439

Closing the Loop for Automotive Plastics — Sustainable Paint-Removal Technology to Realize Car-to-Car Recycling with High-Quality PCR 451

Materials in Electric Drivetrain/
Materialien im elektrischen Antriebsstrang
New Bonding Technology Opens New Technical Opportunities for Hybrid Power Electronics 459

Sustainable, new and useful: Pentatonic Green+ plastic battery housing 473
Nachhaltig, neu und nützlich: Kunststoffbatteriegehäuse Pentatonic Green+ 489

Sustainability 2/Nachhaltigkeit 2
Driving Sustainability with Simulation – Mercedes-Benz frontend crash absorber structure with Borealis Fibremod™ PP 505
Mit Simulation zu mehr Nachhaltigkeit – Mercedes-Benz energieabsorbierendes Strukturelement im Frontend mit Borealis Fibremod™ PP 515

Recyclate use in the painted radiator grilles of the Audi A3 with implementation of a „post industrial closed-loop“ approach 525
Rezyklateinsatz in den lackierten Kühlerschutzgittern des Audi A3 mit Realisierung eines „post-industrial closed-loop“-Ansatzes 543

Market Requirements in the Plastics Industry/
Marktanforderungen in der Kunststoffindustrie
Implications of increasingly diverse markets & customer requests on a globally active automotive tier 1 561

Method for determining the cost impact of tolerances on plastic components – How much does accuracy cost? How much does precision cost in the injection-molding process? 575

Methode zur Ermittlung der Kostenauswirkungen von Toleranzen an Kunststoffbauteilen – Was kostet Genauigkeit? Wie viel kostet Präzision im Spritzgussprozess? 597

Keywords: nachhaltige Kreislaufwirtschaft, hochwertige PCR Regranulation, Sicherheitsglas durch TPE, Innenraum, Stoßfänger, Audi A5, Formfüllprozess thermoplastischer Pressbauteile, smartes KI-gestütztes Engineering, Kunststoffbatteriegehäuse Pentatonic Green+, energieabsorbierendes Strukturelement, lackierte Kühlerschutzgitter, Spritzguss, Materials Engineering, Future Sustainable Car Materials, Post-consumer recyclates, high-quality PCR regrinds, core-back foam injection molding, TPE safety glass, Porsche adaptive front diffuser, innovative EMI-Shielding plastics, Closed-Loop Recycling, vacuum forming, Reliable Virtual Prototyping, Smart AI-Driven Engineering, DC-DC converter application