News from the United States (Newsletter "Plastics Focus" January 9, 1995): Whether it is interior, exterior, structural, or power-related, automakers are looking to make it lighter. It is the main way for them to increase the fuel efficiency of their new vehicles to meet increasingly demanding government regulations. Plastic composites are playing an increasingly important role in lightweighting as manufacturers figure out economical methods to produce components to replace heavier metal parts. By consolidating parts and saving on assembly, the higher material costs for composites can be made insignificant. Next big target for metal replacement is in structural parts. Ford recently unveiled a prototype minivan body made from six molded composite components; all the parts are made by resin transfer moulding vinylester resin with continuous strand mat reinforcement over a low-density foam core. Only the front-end engine framework remained in metal. In Europe, the MOSAIC (Matériaux Optimisés pour une Structure Automobile Innovant la Conception) project has been developing innovative body and frame components. One result is a thermoset composite front end-frame developed by DSM; the corrosion-proof structure provides a weight saving of more than 20% without compromising passenger safety.

Under the hood, thermoplastic composites are making gains in components like intake manifolds and engine covers. To meet the needs of this hot growth area on both sides of the Atlantic, Freudenberg-NOK (developers of the Cadillac Northstar intake manifold) and Amkey (whose industrial operator for Europe is Mecastar, of Monaco) have formed a European-American joint venture. Auttocom LLC, 51% owened by Freudenberg-NOK, will be based in Plymouth, MI, and will focus on composites air-fuel management systems, engine cover systems, transmission, and other powertrain components. The company expects the market for powertrain composites to grow to $ 1.2bn by 1997.

A polypropylene composite with natural fiber reinforcement will be marketed to North American automakers by C.E. Automotive Systems (a joint venture between Cambridge Industries of Madison Heights, MI, and EMPE Werke of Geretsried, Germany). EmpeFlex will be targeted at interior applications like door-trim panels, package shelves, garnish mouldings, consoles, and seat backs. It is matformed in conventional compression moulding equipment, and can be decorated and provided with retainers and fasteners during the moulding cycle. The non-abrasive reinforcement makes the composite more easily recyclable than materials containing glass fibers.