Automotive
Overview automotive applications
Automotive exterior
BASF’s plastics portfolio covers a wide range of materials for automotive exterior applications, including flat and complex-shaped components like glass roofs, body panels, and structural components. Our Engineering Plastics and TPU enable long-lasting components that are UV and weather resistant, withstand high temperatures and show attractive design.
Materials used for lighting systems show an excellent surface as well as fogging behavior. Within its Polybutylene terephthalate portfolio, BASF offers several grades for these purposes: With Ultradur® B 4560 bezels can be directly metallized. Ultradur® HGL IV are premium PBT grades with excellent fogging behavior and demolding properties. Parts made of Ultradur® S4090 G4 can show a textured surface or metallic effects. For structural frames of LED modules,Ultradur® B4040 G10 is the PBT of choice.
The aromatic Elastolit® R 8919 (PU) is a two component RIM-system for automotive glass encapsulations. It provides high-quality surfaces with tailored UV- and weather-resistance. Its outstanding resin flowability enables the encapsulation of large glass panes with a high degree of design freedom in shape, thickness and geometry. The perfect adhesion of these systems to treated glass surfaces and inserts (metals and plastics) supports the integration of various functions and the reduction of process steps.
For door parts like handles, latches or brackets as well as structural stiffeners and locking mechanisms inside the door, UV-stability and a good, long-lasting surface quality are as important as stiffness and strength. Ultramid® B3GM35 (PA) is the material of choice when it comes to UV-stable door handles – painted or unpainted. Ultramid® B3WG6 GIT (PA) shows excellent surface quality and is also optimized for high flowability and good paintability.
For mirror parts like brackets, shells and bases requiring high strength and stiffness, the highly filled PBT grade Ultradur® B4040 G10 (PBT) is a perfect match. It shows a good surface quality for sliding parts and like Ultramid® B3WG13 HPX (PBT) and Ultramid® D3WG12 HMG (PBT), it can replace metal in these exterior applications.
Due to their outstanding flowability, the hard and tough-elastic Elastolit® R (PU) as well as the high-strength Elastolit® K (PU) systemssystems, tailor-made to produce body panels via the RRIM process, permit even the most challenging designs. The components pair their superlative quality with low weight. They can be readily painted thanks to their Class A surface. Their excellent price/performance ratio contributes significantly to the success of small-series components in cars and commercial vehicles.
For roof frames and roofracks accurate shaping is as important as very good UV-stability, superior surface finish, dimensional stability and high stiffness. To meet these requirements BASF offers Ultramid® B3WG8 XCD (PA), Ultradur® S4090 G4 (PBT) and Ultradur® B4040 (PBT) with different glass fiber contents characterized by a good flowability. There are optimized grades for visible or non-visible sunroof frames, covers as well as for wind deflectors.
Powertrain
BASF has been a globally reliable and accepted partner for the automotive industry for decades. The use of Engineering Plastics, Polyurethane systems and Additives leads to advantages like weight reduction, functional integration, improved NVH-performance (NVH=noise, vibration, harshness) and cost savings.
Cellasto® (PU) absorbs the sudden torque variations and vibrations of electric motors and combustion engines. Guaranteeing lasting performance through chemical and abrasion resistance, Cellasto® (PU) improves operator comfort when used in motor mounts.
Cellasto® (PU) drastically improves NVH performance with amplitude-dependent damping. Thanks to optimal rotational angle properties, better alignment compensation is achieved, saving cost and weight. In drivetrain components, Cellasto® (PU) prevents resonant and transient overloads, allowing smoother power delivery with outstanding NVH qualities.
Lowering global carbon emissions, reducing the total cost of ownership, transforming the transportation experience- eMobility is yielding innovations that make our lives more sustainable. Many eMobility solutions can only be implemented successfully by using highly versatile engineering plastics, polyurethane systems and specialty elastomers. BASF’s dedicated eMobility team includes engineering, design and material experts who can help you choose the best material and the best grade for your application. Learn more about eMobility here.
In plug-in- or fully hybrid vehicles, increasing the use of plastics components can compensate the weight of the battery and increase efficiency. By continuously developing new products in collaboration with our customers, our portfolio adapts to trends and changes in the market.
Alongside the continued development of cars with more efficient internal combustion engines, chemistry is making an important contribution to fuel cell drive concepts. Thermal and chemical resistance, dynamic stiffness, impact strength, and good long-term performance are prerequisite for materials that are used in alternative powertrains.
Special Ultramid® EQ (PA) grades have successfully been used to manufacture a number of fuel cell components, providing exceptional purity requirements associated with sensitive applications in the electronics industry. In the case of the media distribution plate and the water separator unit, which is exposed to a wide variety of media through the cooling water, air and hydrogen channel, Ultramid® (PA) offers excellent resistance, while at the same time meeting all requirements regarding the purity of the material.
Special Ultramid® EQ (PA) grades have successfully been used to manufacture a number of fuel cell components, providing exceptional purity requirements associated with sensitive applications in the electronics industry. In the case of the media distribution plate and the water separator unit, which is exposed to a wide variety of media through the cooling water, air and hydrogen channel, Ultramid® (PA) offers excellent resistance, while at the same time meeting all requirements regarding the purity of the material.
Replacing metal parts with plastics makes cars with combustion engines more efficient. BASF’s engineering plastic Ultramid® (PA) with its high quality and safety features is used in many established plastic applications such as air intake manifolds, oil pans, and components for thermal management. The polyamide offers high thermal stability, dynamic strength, impact resistance and long-term performance.
Engine covers need to combine effective acoustic performance with durability and resistance to the demanding conditions of the engine compartment. Elastofoam® (PU) provides an integral skin foam solution that combines a lightweight foam core with a robust, attractive surface in a single material system. Its good sound absorption helps reduce engine noise, while its resistance to heat and various media supports long-term performance in demanding environments.
The one-shot production process creates the foam and protective skin in a single step, eliminating the need for an additional beauty cover and simplifying manufacturing. This combination of acoustic performance, durability, design freedom and efficient processing makes Elastofoam® I (PU) an attractive solution for modern engine covers.
Automotive interior
With BASF’s polyurethanes and engineering plastics, modern and innovative automotive interior designs can be realized. Besides high-class surfaces, smart haptics, improved acoustics and long service life, the materials offer efficient production, global availability, and reliable service.
Instrument panels are safety-relevant parts with extreme requirements. The foam must provide high durability even in humid and hot environments. even in humid and hot environments. Elastoflex® E (PU) is well-suited for this purpose. The current portfolio for closed- and open-mold technologies offers low density solutions down to 100 g/l and fast demolding times down to 70s. Foaming in gaps smaller than 5 mm can be realized. Emissions are extremely low fulfilling VDA278 and chamber test requirements. Special soft grades are available fulfilling harsh heat and humid aging tests requested by OEMs.
Steering wheels made of the flexible integral foam Elastofoam® I (PU) have a soft, comfortable touch combined with a tough outer skin. They are wear-resistant and durable, unaffected by sweat, sun cream or cleaning agents. State-of-the-art low emission systems offer a significant weight reduction.
Car headliners are the biggest surface to absorb sound and reduce vibrations, though available space is limited. BASF thermoformable foam systems Elastoflex® E 3943 (PU) are perfectly suited for this application. The low density foam systems down to 22 g/l offer outstanding acoustic properties while providing high stiffness and very low emissions. The ISO 116 product line complements the portfolio by lamination adhesives for high productivity and low scrap rate.
Elastoflex® E 3532 (PU) is the ideal resin to realize extremely lightweight honeycomb-sandwich structures due to easy and fast processing. Regardless of part size, our thermo-activated systems ensure thorough wetting of the fibers, a firm bond with the sandwich core and rapid curing. Due to its excellent mold-release properties, tailored rheological profile and low temperature curing mechanism, enable resource-efficient production throughout the entire manufacturing process.
BASF provides fully formulated Elastoflex® W (PU) systems or special isocyanate solutions for comfortable seats with high productivity even at low densities down to 40g/l. Foam hardness is directly adjustable on the application machines in a wide range. Different hardness zones in a seat allow a combination of strong seating support with a soft feel for increased comfort. Elastoflex® W (PU) foam systems are extremely durable under dynamic loads for long service life.
Turning lightweight ambition into reality: the composite seatback and seat structure using Ultramid® B3ZG7 CR (PA) as a powerful metal-replacement solution - unlocking greater design freedom, reducing vehicle weight, accelerating cycle times, and paving the way for smarter, more streamlined manufacturing.
Turning lightweight ambition into reality: the composite seatback and seat structure using Ultramid® B3ZG7 CR (PA) as a powerful metal-replacement solution - unlocking greater design freedom, reducing vehicle weight, accelerating cycle times, and paving the way for smarter, more streamlined manufacturing.
Acoustic comfort is becoming increasingly important for passenger wellbeing and overall vehicle quality. At the same time, more stringent NVH (noise, vibration, and harshness) requirements -particularly for NEVs (new energy vehicles) - are creating a growing need for lightweight, high-performance acoustic solutions.
Elastoflex® W (PU) addresses these requirements in applications such as carpets, dashboards, and e-motor insulation covers by significantly improving sound absorption and damping performance. Its tailored acoustic properties, low density, good processing behavior, and low emissions are generated in a for state-of-the-art back-foaming processes, helping automotive manufacturers combine enhanced acoustic comfort with efficient, lightweight component design.
Elastoflex® W (PU) addresses these requirements in applications such as carpets, dashboards, and e-motor insulation covers by significantly improving sound absorption and damping performance. Its tailored acoustic properties, low density, good processing behavior, and low emissions are generated in a for state-of-the-art back-foaming processes, helping automotive manufacturers combine enhanced acoustic comfort with efficient, lightweight component design.
The interior is where every journey becomes an experience. Surfaces do more than shape the look of a vehicle - they invite touch, create a sense of comfort and quality, and need to stay beautiful through everyday life. At the same time, tomorrow’s interiors call for smarter materials with lower emissions and a more sustainable footprint.
Haptex® (PU) brings these qualities together in a solvent-free polyurethane synthetic leather designed for modern automotive interiors. Its soft, premium touch meets outstanding durability and flexibility - even at low temperatures - while low VOC and odor contribute to a more pleasant interior environment.
And its benefits go beyond what you can see and feel. Solvent-free and organotin-free technology enables more resource-efficient production, helping reduce product carbon footprint as well as water and energy use. With the freedom to combine aesthetics, comfort, performance and sustainability, Haptex® (PU) opens new possibilities for creating the next generation of vehicle interiors.
Haptex® (PU) brings these qualities together in a solvent-free polyurethane synthetic leather designed for modern automotive interiors. Its soft, premium touch meets outstanding durability and flexibility - even at low temperatures - while low VOC and odor contribute to a more pleasant interior environment.
And its benefits go beyond what you can see and feel. Solvent-free and organotin-free technology enables more resource-efficient production, helping reduce product carbon footprint as well as water and energy use. With the freedom to combine aesthetics, comfort, performance and sustainability, Haptex® (PU) opens new possibilities for creating the next generation of vehicle interiors.
Chassis, structural and body in white applications
The automotive chassis accounts for roughly one-third of a vehicle’s mass and forms the structural foundation to which the interior, exterior, powertrain, and electronic systems are mounted.Our product portfolio provides solutions to reduce weights and improve strength, energy management, and NVH (Noise, Vibration, Harshness) damping.
In EVs it is imperative to limit the intrusion into the battery compartment during an impact event. Continuous fiber systems using our polyurethane Elastocoat® (PU) offer the ability to create structures with steel-like strength at only 30% of the weight while allowing efficient integration with dissimilar materials.
BASF offers solutions to manage kinetic energy for high deformation events with Ultramid® (PA) in the form of foams or impact modified injection or extruded grades.
BASF offers solutions to manage kinetic energy for high deformation events with Ultramid® (PA) in the form of foams or impact modified injection or extruded grades.
Electric vehicles generate new high-frequency noise patterns due to the high rotational speeds of electric motors. BASF's Ultramid® (PA) helps reduce sound and vibration transmission when replacing conventional metallic suspension components.
Elastoflex® (PU) ultralight BIW NVH foam fills the cavities of the automotive body to absorb and block noise transmission to the automobile interior. Cellasto® (PU) microcellular polyurethane elastomers 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.
Elastoflex® (PU) ultralight BIW NVH foam fills the cavities of the automotive body to absorb and block noise transmission to the automobile interior. Cellasto® (PU) microcellular polyurethane elastomers 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.
Performance of metal structures is improved when using BASF’s thermoplastics Ultramid® (PA) and Ultradur® (PBT). Reinforcing metal profiles delays structural failure and can increase peak load performance by up to 300%. Elastolit® D (PU) structural foam enables significant weight reduction through efficient cavity filling. Ultramid® Expand (PA) is suitable for areas such as complex 3D shapes, cell holders, and battery protection.
BASF's Ultramid® (PA) polyamide portfolio for automotive air suspension components. By converting metal components to Ultramid® (PA) and leveraging BASF’s advanced simulation engineering, Ultrasim®, complex geometries can be designed with greater freedom while achieving lightweighting, faster development cycles, and high productivity, while maintaining ride comfort and contributing to road safety.
Automotive Electrics & Electronics
Innovation in automotive design is significantly driven by electrical, electronic and mechatronic systems. Engineering Plastics and Polyurethanes from BASF enable innovative solutions for automotive electrics and electronics. Both material groups are indispensable when it comes to safety, comfort and energy efficiency in modern vehicle concepts.
Like sensitive electronic components, sensors have to withstand high temperatures in all climate zones. Besides eMobility, automated driving is gaining importance and sensors are key components for vehicle performance. As sensors play a greater role, the challenges for these sensors in ADAS will continue to increase. Tailor-made Engineering Plastics, like Ultradur® RX (PBT) are resistant to external impacts like spray water, oils or road salt while reliably blocking or transmitting radar waves from other vehicles.
The electronic control unit housings must protect sensitive automotive electronics and remain functional in all climate zones. Hot damp conditions, spray water and road salt increase the requirements on the plastic. Therefore, the level and duration of the stress are key factors as to whether or not an application is feasible. Ultradur® HR (PBT) is the ideal choice for performance in challenging environments.
With the increasing use of actuators, such as in seat control, automatic lighting controlling or door locks, the comfort for the driver is also growing. Due to miniaturization and functionalization of components, actuators are becoming smaller and more complex, which demands materials with high mechanical performance such as Ultraform® (POM), Ultradur® (PBT) or Ultramid® Advanced (PA) from BASF. They offer high dimensional stability, wear resistance and are optimized for complex components in actuators.
Speed sensor cables for ABS and ESP systems use cable sheathings of Elastollan® (TPU) to provide a secure flow of information – even in areas of exposure to water, vibration and low temperatures. Elastollan® (TPU) is also used for charging cables as flame retardant material.
A cable harness is typically limp and has to be transformed into a specific, three-dimensional, pre-formed geometry using, for example, cable conduits or tape. With Elastofoam® (PU) the foaming process provides greater flexibility, provides mechanical protection and the integration of mounting elements is possible.
A cable harness is typically limp and has to be transformed into a specific, three-dimensional, pre-formed geometry using, for example, cable conduits or tape. With Elastofoam® (PU) the foaming process provides greater flexibility, provides mechanical protection and the integration of mounting elements is possible.
High-voltage connectors can often be identified by their typical orange color. Ultradur® (PBT) is color stable and resistant to thermal aging. The color coding of the individual components is safety-relevant: It needs to remain highly visible for at least ten years. While being part of the non-halogenated flame-retardant portfolio, the BASF polybutylene terephthalate (PBT) offers high hydrolytic resistance and excellent electrical insulation (CTI 600).
eMobility
Backed by decades of engineering expertise and built with superior eMobility Performance Materials, your applications will meet the highest standards for safety, durability, and mechanical performance when choosing BASF as a supplier.
Learn more about eMobility
Learn more about eMobility
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FAQ
Q: What materials are best suited for automotive electronics applications?Automotive electronics require materials that combine electrical insulation, heat resistance, mechanical strength, and long-term dimensional stability. BASF Engineering Plastics, including Ultramid® (PA) and Ultradur® (PBT), are designed to meet these requirements in applications such as connectors, sensors, control units, power electronics, and fuse boxes.
Q: How can polyurethanes and engineering plastics be used in automotive interior design?
With BASF’s polyurethane and engineering plastics solutions, modern and innovative automotive interior designs can be realized. They can be used in a variety of parts, such as instrument and door panels, steering wheels, and seating.
Q: How can weight be reduced in vehicles?
Replacing aluminum and steel parts in automotives with engineering plastics such as BASF’s Cellasto® (PUR), Ultradur® (PBT) or Ultramid® (PA) reduces a vehicle’s weight significantly.
Q: Can plastic be used for automotive exterior parts?
Yes, engineering plastics, polyurethanes and thermoplastic polyurethanes such as BASF’s Elastolit® (PU), Ultradur® (PBT) or Cellasto® (PU) can be used for exterior parts in automotives such as lighting systems, window encapsulation, or door parts.
Q: Which material is suitable for automobile chassis?
Engineering plastics, polyurethanes and thermoplastic polyurethanes can be used in automotive chassis to ensure powertrain protection, noise management, and lightweight structure. BASF’s solutions for chassis include solutions such as Cellasto® (PU), Ultradur® (PBT), Elastoflex® (PU) which offer reliability and durability in chassis.