The automotive industry is the largest consumer of technical plastics in the world – it is responsible for about 25% of global consumption of engineering polymers. The average mid-size passenger car today contains 150-200 kg of plastic, and this number is growing with each new generation of models.
There is one thing behind this trend: weight. For every kilogram of reduced vehicle weight, it means approx. 0.015 l/100 km less fuel consumption and a proportional reduction in CO₂ emissions. With increasing EU regulatory requirements (95 g CO₂/km target for fleets), OEMs have no choice but to replace metal with plastic wherever strength and safety allow.
In this article, we discuss how polyamide is responding to these challenges: which components are already being made of PA, what trends are shaping the industry, and what electrification means for the demand for technical plastics.
Trends driving material change in the automotive industry
CO₂ reduction and lightweighting
EU emission requirements force manufacturers to look for every gram of weight savings. Replacing the steel bracket with polyamide reduces weight by 40-60% while maintaining the required strength – and this is the kind of replacement that is now standard in the design phase of new models.
Lightweighting is not limited to body elements. It also affects the drivetrain, suspension, auxiliary systems and electrical system – areas where polyamide is gradually replacing aluminium, cast iron and steel.
Electrification: new requirements, new opportunities
Electric vehicles (BEV) and hybrid vehicles (PHEVs) are changing the map of plastic components. The internal combustion engine and gearbox are disappearing – but completely new groups of components are emerging: battery housings, battery thermal management systems, high-voltage connectors, charging modules.
All these elements place high material requirements: thermal resistance, electrical insulation, flammability class, electrolyte resistance. Polyamide – especially PA66 and high-temperature varieties – is becoming the material of choice for many of them.
Increasing the complexity of electrical systems
A modern car contains 3-5 km of wiring and hundreds of electrical connectors. Each connector, connector housing, and harness mounting element is a potential component with PA66. Electrification further strengthens this tendency – high-voltage systems require connectors with a higher flammability and insulation class.
Polyamide in a car: a map of components
Polyamide is present in virtually every car system. Below is an overview of the key areas of application.
Components under the bonnet
This is the harshest environment in a car – ambient temperature of 120-150°C, contact with oils, fuel, coolant (glycol) and aggressive exhaust gases. The standard is PA66 GF30 and PA66 GF50, whose HDT exceeds 220–240°C.
Typical components:
- Air and oil filter housings
- Cooling system connectors and tanks
- timing and valve covers
- Cable harness brackets and holders
- thermostat and EGR valve housing
- intake manifolds – one of the largest PA components in the automotive industry in terms of volume
- Water and fuel pump housings
- turbocharger components (on the cold side)
“The intake manifold with PA66 GF30 is now standard in petrol and diesel engines – 40% lighter than aluminium, cheaper to produce and functionally identical.”
Vehicle interior components
The interior combines aesthetic and mechanical requirements. The temperature is lower (up to 80-90°C), but UV resistance, fatigue strength and surface quality become crucial. PA6, PP and ABS are used here, depending on the application.
Typical components:
- interior and exterior door handles (PA6 or PA66)
- window lifter mechanisms (gears, guides – PA6)
- steering column and steering components
- dashboards and instrument housings (PP, ABS)
- seat elements (guides, handles – PA6)
- clips, snaps, upholstery elements (PP, PA6)
- Pedals Levers (PA66 GF)
- hinges and door elements
Electrical and electronic components
Electrical connectors are one of the largest markets for PA66 in the automotive industry. The growing number of controllers, sensors, and ADAS systems is increasing the demand for connector housings and insulation components.
Typical components:
- connector housings – PA66, PA6T
- housings for ECUs and electronic modules
- Cable harness holders and guides
- fuse and relay housings
- elements of high-voltage connectors (BEV/PHEV) – PA66 FR (flame retardant)
- insulators and spacers on PCBs
For high-voltage connectors in electric vehicles, a flammability class of UL94 V0 and an electrical strength of more than 20 kV/mm are required – which is met by the special grades PA66 FR.
Certification requirements in automotive
The automotive industry is one of the most demanding suppliers in terms of certification and qualifications. OEMs and Tier 1 manufacturers typically require:
- IATF 16949 – quality management standard for automotive suppliers. It requires, m.in, APQP (Advanced Product Quality Planning), PPAP (Production Part Approval Process) and process monitoring in the SPC system. This is the foundation of any component supplier’s qualification for OEM.
- PPAP (Production Part Approval Process) – a formal process of approving a new part or a change in the production process. It includes material documentation, measurement reports, dimensional and property tests, samples from serial production.
- Endurance and environmental tests – each automotive component undergoes a series of tests including, m.in: climate test (temperature/humidity cycle), vibration test, chemical resistance test (contact with oils, fuel, coolant), impact and fatigue tests.
- OEM Material Requirements – Car manufacturers (VW, BMW, Stellantis, Toyota, and others) have their own material specifications that narrow down the acceptable grades of plastics. The supplier must use material from the approved list and document each production batch.
Case study: 40% reduction in bracket weight while maintaining strength
Background: A Tier 2 component manufacturer has commissioned a redesign of the steel radiator hose mounting bracket. The element worked at a temperature of 110°C, under constant tension from the cable tie, in contact with the coolant.
Material problem: stainless steel – durable but heavy (weight approx. 85 g) and expensive to produce (punching + bending + electroplating). The OEM expected to reduce cost and weight while maintaining function and durability.
Material: PA66 GF30 (glycol contact grade, HDT 235°C according to ISO 75 at 1.8 MPa).
Structural changes: redesign of the geometry taking into account the specificity of the material – addition of stiffening ribs, change of cross-sections in stress zones, elimination of sharp corners.
Results:
- Element weight: 85 g → 51 g (40% reduction)
- Unit cost: 28% decrease (elimination of electroplating and punching operations)
- Element HDT: 235°C vs required 120°C – safety margin 2×
- Climate tests (1000 h at 110°C with glycol): no degradation, dimensions within tolerance
- Implementation: 11 weeks from order to PPAP approval
Conclusion: the conversion of metal → plastic with the right design of the workpiece and the selection of material gives a simultaneous reduction in weight, cost and number of technological operations.
The future: polyamide in electric vehicles
Electrification of the automotive industry is an opportunity, not a threat for polyamide. Some components related to the internal combustion engine are disappearing, but new groups with higher material requirements and larger volumes are emerging.
- Battery module housings – A BEV battery system contains hundreds of cells, and each module requires an enclosure with good electrical insulation, flammability class V0, and lithium electrolyte resistance. PA66 GF and hybrid PA/PPA varieties are serious candidates here.
- High Voltage Connectors and Systems – An operating voltage of 400V or 800V requires components with electrical strength and flammability class clearly above 12V standards. PA66 FR and PA6T FR are materials designed exactly for these requirements.
- Battery thermal management systems – battery cooling system stubs, tanks and pump housings are a direct analogy to engine cooling system components – and the same material: PA66 GF.
- Electric motors and converters – coils, traction motor housings and winding insulators require plastics with a high thermal continuity (RTI) class. Classic PA66 can be too weak here and high-temperature materials – PA46, PA6T, PPA – come in.
“An electric vehicle contains fewer engine components than an internal combustion vehicle, but more electrical connectors, electronic housings and energy management components – all made of polyamide.”
FAQ – frequently asked questions
What polyamides are most often used in the automotive industry?
PA66 GF30 dominates the components under the hood and electrical connectors. PA6 is used in interiors, door handles and mechanical components. PA66 FR is the standard for high-voltage connectors in BEV/PHEV. For the most demanding thermal applications (above 180°C continuous), PA66/6T, PA6T or PPA are used.
Are plastics safe in a car?
Structural safety (bodywork, pillars, floor) is still based on steel and aluminum. Plastics used in the automotive industry are functional components – housings, brackets, connectors, guides – designed and tested for specific loads. Each component undergoes a series of endurance, climate and environmental tests before it is made into a production vehicle.
What is IATF 16949 and does every manufacturer need to have one?
IATF 16949 is a quality management standard specific to the automotive industry – an extension of ISO 9001 with APQP, PPAP, SPC and other requirements. IATF certification is required by most OEMs and Tier 1 manufacturers from their direct suppliers. Without it, it is difficult to enter the automotive supply chain.
How long does it take to qualify a new component in the automotive industry?
The standard PPAP process takes 3-6 months from design approval to acceptance of the first batch samples. For security components or completely new applications, the process can be longer. Proper preparation of documentation and samples shortens the time – errors at the PPAP stage can extend the project by further months.
Will polyamide last in an electric vehicle with a high-voltage battery?
The standard PA66 has an electrical strength of 20–30 kV/mm and a cross-resistivity of 10¹³–10¹⁴ Ω·cm – this is sufficient for most connectors and housings in a 400V system. For components directly exposed to high voltage, special grades of PA66 FR with additional electrical certification are used. When designing BEVs, always verify the electrical properties of a specific material grade.
Are you producing automotive components or planning to enter the automotive supply chain? Polyamide Plastics carries out injection molding production of PA6, PA66 and technical plastics for customers from the automotive sector – from prototype through PPAP to series. Contact our technical department.