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Automotive

Driving forward plastics solutions for chassis, structural applications, and body in white

The automotive chassis is roughly one third of the mass of vehicle and forms the structure where the interior, exterior, powertrain, and electronics finds mounting. It is the first defense in protecting the occupant and components protection. The incumbent materials are primarily metal based offering an opportunity to use composites to reduce weight and enhance performance (strength, energy management, NVH damping, etc.) with our expanding product portfolio.

Watch the video on the right to get an overview on our chassis, structural applications, and body in white solutions.

Our solutions

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» Applications

Versatile applications for automotive chassis and body in white solutions

Whatever your specific needs for the variety of different chassis and BIW solutions are: BASF connects new material developments and services in order to create system solutions which give your chassis and BIW solutions the distinctive advantage.

A virtual car showcasing battery protection features for the chassis made from Elastocoat® and Ultramid®.

Occupant and future powertrain protection

eMobility is the lead movement in the automotive industry to address our need to make our lives more sustainable. Due to the size and location of the batteries it is imperative to protect the passengers by limiting the intrusion into the battery compartment during an impact event. Continuous fiber systems using our polyurethane Elastocoat® offers the ability to create structures with the strength of steel at third of the mass with no concern of mixing with dissimilar materials. In addition to offering structure, BASF offers solution to manage kinetic energy for high deformation events with our Ultramid® in the form of foams or impact modified injection or extruded grades.

Engine mount made from BASF Ultramid® which reduces noise. 

Noise and vibration management

eMobility brings additional challenges to noise and vibration abatement. Electric motors reduce vibration at lower frequencies but introduce new higher frequency noises due to the high rpm motors. BASF Ultramid® reduces sound and vibration transmission when replacing metallic engine suspension mounts due to the inherent damping characteristics of polymers. BASF Elastoflex® ultralight BIW NVH foam is used today to fill the cavities of the automotive body to absorb and block noise transmission to the automobile interior. Cellasto ® microcellular polyurethane elastomers are used in chassis and suspension applications to isolate vibrations and reduce structure-borne noise. Their superior damping behavior across a wide frequency range makes them ideal for managing NVH challenges in electric vehicles.

A virtual car showcasing enhanced metal profiles for the chassis, made from Ultramid®, Ultradur®, and Elastolit® D.

Lightweight body structure enhancement

To improve the performance of metal structures, BASF’s Thermoplastic Ultramid® and Ultradur® is used to reinforce the metal profiles by delaying the failure of metal structure leading to an increased peak load up to 300%. This can also be accomplished by filling the cavity with BASF Elastolit® D structural foam.

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Powertrain mounts made from Ultramid® A3WG10, designed to manage high torque and motor vibrations.
Frontend module crafted from BASF's Ultramid®, providing enhanced performance and functionality for modern vehicles

Powertrain mounts

Motors and Transmission generate the power and torque to drive the vehicle.  The mounts have the job to hold the high torque motor in place and absorb the vibration generated to ensure it is not transferred to the passengers in the cockpit.  Here Ultramid® A3WG10 HP has the advantage compared to traditional aluminum and steel mounts and brackets.  The polymer and glass fiber composite offers 10-30 times the amount of damping (the ability to absorb vibration) due to the viscoelastic behavior of the polymer.

Frontend modules

BASF Ultramid® has been part of the solution to integrate components and functionality of the front vehicle structure for over 20 years due to the structure performance at wide range of temperatures (-40°C to 90°C) and its versatility to be used as a sole material or part of plastic-metal hybrid system where Ultramid® is molded over steels stampings to improve the steel performance, handle the attachments of the headlamps, radiator, fascia, and hood latch. Creative engineering has demonstrated Ultramid®’ s ability to be integrated into the front-end collision counter measures through the use of integrated crush cans as part of the frontend module.
Top view of a virtual car highlighting the chassis features made from Ultramid® and Elastolit®.
Foam made from Elastoflex® E and W to manage the Noise Vibration Management (NVH).

Vehicle body reinforcement

The eMobility and autonomous movement is focused on collision avoidance, but accidents do happen and there needs to be countermeasures in place when this occurs.  Fortunately, BASF has solutions to reinforce the body of the vehicle through use of structural inserts using either Ultramid® or Elastolit® D structural foam or replacing the structure using our high strength Elastocoat PU continuous fiber system; all of which improve the integrity of the passenger compartment offering a greater degree of occupant protection and reducing the weight of the vehicle.

Systems for automotive body acoustics

BASF has systems to automotive body acoustics. BASF's Elastoflex®  E (semi-rigid polyurethane foam) and Elastoflex®  W (flexible polyurethane foam) systema are a low density and lightweight solution that minimizes overall impact to vehicle weight and noise transferred to the passenger compartment. Elastoflex® acoustical properties address noise vibration and harshness (NVH) needs set by automobile manufacturers for quieter driving experiences and lighter weight solutions.

Sustainability

As the world moves to a sustainable and circular economy, BASF is supporting car manufacturers and suppliers to the automotive industries achieving their respective goals. BASF products & support are driving lightweight implementation, leading to lower raw material usage and reduced fuel consumption. We provide transparency, as we have mapped the CO2 consumption of over 45,000 of our products. Furthermore, our Sustainability Toolbox offers concrete possibilities to lower the CO2 footprint of our and your products further, as well as to increase circularity. Eager to learn more? Just follow the links below.

Learn more about our sustainable plastics solutions for the automotive industry

Interested? Watch the recording of our webinar

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Detailed material information for chassis, structural applications, and body in white solutions

Polymer based solutions create an automobile chassis to manage the high out propulsion, to maximize occupant protection, reduce vehicle mass, and improve passenger comfort. 

The emergence of eMobility brings new challenges to the chassis to provide mounting for the high torque eMotors, protect the passengers and high-density battery from intrusion during an accident, and minimize sound and vibration from these much higher frequency sources.  BASF’s Polyurethanes Elastocoat®, Elastoflex®  E, Elastoflex®  W and Elastolit®; along with Engineered Plastics Ultramid®, Ultramid®  Expand, and Ultradur® provide solutions with a superior strength to weight ratio compared to metal, manage frontal and side impact events, while providing an environment which the passenger remains in peace.

» Engineering Plastics

Our Engineering Plastics for chassis, structural applications, and body in white solutions

Ultramid® Expand (EPA)

Ultramid® Expand is a particle foam by BASF that is based on polyamide 6. The particle foam excels with a wide range of unique characteristics: high temperature-resistance, outstanding stiffness and strength as well as an excellent chemical resistance, e.g. in contact with fuels, oils and lubricants. Additionally, the closed cell foam structure offers an exceptional compressive strength, a requirement for the use in crash relevant components that are exposed to high mechanical demands. Because of this versatility, lightweight applications are possible as well.

Discover Ultramid® Expand

Ultradur® – Polybutylene terephthalates (PBT)

The Ultradur® product line of partially crystalline, thermoplastic and saturated polyesters is derived from polybutylene terephthalate (PBT). Ultradur provides strength in applications where high-quality and heavy-duty parts are required - a feature that is particularly important is the low water absorption and thus the fact that the mechanical and electrical properties are largely independent of the moisture content or the climatic surrounding conditions. Particularly for components that are safety-relevant and have to work reliably for the entire lifetime of a component, Ultradur® is indispensable.

Learn more about Ultradur®

Ultramid® – Polyamides (PA6, PA66, PA66/6, PA610, PA6T/6)

The Ultramid® product line offers several grades of molding compounds, available as unreinforced, reinforced with glass fibers or minerals, or reinforced with long-glass fibers for special applications. Ultramid® is noted for its high mechanical strength, stiffness and thermal stability. The grades are based on PA6, PA66, PA66/6 or various other co-polyamides and are recommended for applications that need superior durability.

Learn more about Ultramid®

» Polyurethanes

Our PU systems for chassis, structural applications, and body in white solutions

Elastoflex® W – Flexible Foam System (PU)

The flexible foam system Elastoflex® W decisively contributes to car comfort and improves the sound impression in the driver’s cabin. In comparison to other acoustic solutions, Elastoflex® W performs not only as sound absorber, but also dampens sound from outside the car by visco-elastic energy dissipation. Especially designed foams resist also high temperatures and media contact. These foams are widely used in direct contact to the engine as NVH (noise, vibration, harshness) and heat management solution. Engine covers with this open cell foam structure lead to weight reduction with a density on only 15g/L.

Learn more about Elastoflex® W

Elastoflex E – Semi-Rigid Foam System (PU)

Although invisible, Elastoflex® E semi-rigid foams contribute extensively to the valuable appearance in car interiors, since the foam can be found behind most skin surfaces and causes a pleasant, soft and elastic touch. It needs to fill even smallest gaps between carrier and skin, e.g. in instrument and door panels as well as in armrests. Elastoflex® E has excellent mold-filling and very robust processing properties. The semi rigid foam systems offer fast demolding times and can be combined with all skin types, individually designed for all special OEM requirements. Although applications are diverse, it is BASF’s goal to provide one system for many parts in order to reduce customers’ complexity and cost structure.

Learn more about Elastoflex® E

Elastoflex® E and Elastolit® D – Semi-structural foams (PU)

The low-density Elastoflex® E and Elastolit® D semi-structural foams are designed for producing very light and stiff composite as well as sandwich structures for various interior and exterior applications such as load floors, interior lining parts, roof modules and engine hoods. Reinforced with long-glass fibers in state-of-the-art composite processes, thin-walled parts with good mechanical properties and light in weight can be realized. Such composite substrates can be combined with various surface materials like textiles or thermoplastic films, either by back-foaming or adhering.

Learn more about Elastoflex® E and Elastolit®

Elastocoat® (PU) – Continuous fiber matrix/binder

Elastocoat® is a high-tech spraying system for the reliable and lasting protection of all surfaces.  As a quick, efficient and lasting seal, it is ideal for chassis and body in white requirements. Also its rapid application in comparison to other materials is an advantage.

Elastocoat® is also the tradename of BASF’s polyurethane matrix system used in continuous fiber pultrusion or resin transfer molding for components requiring the highest to strength ratio and excellent energy management.

Learn more about Elastocoat®

» Specialty Elastomers

Automotive Chassis Applications
Enhance vehicle comfort with Cellasto's® noise, vibration and harshness (NVH) material solutions designed for chassis
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Two individuals working in front of two monitors to design a product using Ultrasim®.

That is where part geometry, part manufacturing process, and material selection need an integrated approach. With Ultrasim® we offer you versatile and flexible CAE competence for your innovations using BASF plastics. Our analysis of component concepts on a virtual basis starts with your manufacturing process to understand the material behavior in the finished component, this is coupled with the appropriate materials and detailed material models, ranging from the virtual prototype and ideal manufacturing process to the finished mass-produced component.

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