Borealis Glass Fibre Reinforced Polypropylene Compound Achieves Market First for VW “Under-the-Bonnet” Component

Borealis' unique glass fibre reinforced polypropylene (PP) compound XMOD GB306SAF is helping Volkswagen (VW) and parts manufacturer MAHLE Filter Systems UK improve production cost-efficiency and achieve both performance and environment-friendly benefits for the Air Intake Manifolds (AIMs) used on a wide variety of VW car models. Their choice of high-performance XMOD GB306SAF from Borealis, makes VW the first automotive OEM to switch from glass reinforced Polyamides to PP for this high tech under-the-bonnet application.

XMOD GB306SAF is a high stiffness 35% glass fibre reinforced PP compound that offers long-term high heat and chemical resistance, vibration resistance combined with high fatigue and a broad operating temperature between -40°C and +120°C. Existing manufacturing equipment and processes for AIMs can be used. In addition, as a lighter-weight, lower density material it enables weight reductions for AIMs of up to 15%, while offering exceptional sound damping that surpasses current acoustic behaviour for AIMs.

XMOD GB306SAF contributes to lowering overall production costs for AIM parts through its lower material price and its lightweight benefits of improved handling and reduced energy usage. Lower processing temperatures and the lack of pre-drying further reduce overall energy consumption and eliminate manufacturing steps, achieving more cost-effective production.

"Polypropylene is already the most widely used thermoplastic material in cars and under the bonnet", adds Harald Hammer, Vice President Business Unit Mobility. "As proven with the Air Intake Manifold, this XMOD material leads the way in further diversifying automotive applications for PP, delivering the step change in cost-efficiency, weight reduction and environmental performance the industry requires."