As automotive design evolves, manufacturers increasingly rely on advanced materials to reduce weight, improve durability, and support sustainability goals. Covestro focuses on developing polycarbonate‑based solutions that replace heavier metals, enhance surface performance, and enable circular manufacturing practices. These innovations support automakers seeking to improve efficiency, reduce environmental impact, and deliver premium experiences to consumers.
Material selection plays a critical role in modern vehicle engineering. Components must withstand demanding thermal, mechanical, and environmental conditions while meeting strict cost and performance requirements. Covestro's approach combines raw material expertise with process development, allowing the company to collaborate closely with OEMs and suppliers to create next‑generation components that are lighter, safer, and more sustainable.
One of Covestro's key developments is a thermally conductive polycarbonate designed to replace aluminum and magnesium heat sinks. While metals traditionally offer superior thermal conductivity, polycarbonate provides advantages in emissivity, enabling effective heat dissipation through alternative mechanisms. This balance allows the material to deliver comparable thermal performance while significantly reducing weight.
The use of polycarbonate in heat‑management components supports improved energy efficiency in both automotive and electronic applications. Lighter parts contribute to reduced vehicle mass, which can enhance range and performance in electric vehicles. The material also supports cost reduction by simplifying manufacturing processes and lowering material expenses. These benefits demonstrate how material science can unlock new design possibilities without compromising functionality.
Covestro has also developed a direct‑coating technology applied to polycarbonate lenses and exterior panels. This coating provides a high‑gloss, premium finish while offering self‑healing properties. When the surface is scratched, heat can be applied to restore its appearance, extending the lifespan of the component and maintaining a like‑new finish.
This technology is already in production on vehicles such as the BMW i7, where it enhances both aesthetics and durability. The coating reduces the need for traditional painting or hard‑coating processes, lowering manufacturing costs and minimizing scrap caused by surface defects. By enabling repairability and long‑term visual quality, the solution supports both consumer satisfaction and sustainable manufacturing practices.
A significant advancement in Covestro's sustainability portfolio is the chemical recycling of end‑of‑life tires. Through a specialized process, the rubber from used tires is broken down and converted into virgin‑quality polycarbonate. This material can then be used in applications requiring optical clarity, including headlamp lenses and other transparent components.
The recycling process separates metal reinforcements, fabric layers, and contaminants, ensuring that only the usable rubber is transformed into new material. The high yield of this method makes it one of the most efficient recycling pathways for tires, addressing a long‑standing environmental challenge. By converting waste into high‑value polycarbonate, Covestro supports circularity and reduces reliance on fossil‑based raw materials.
Covestro advances automotive design through innovative polycarbonate materials, self‑healing coatings, and circular recycling technologies. By reducing weight, improving durability, and enabling sustainable manufacturing, the company provides solutions that align with the evolving needs of modern mobility. These developments demonstrate how material science can enhance performance while supporting environmental responsibility across the automotive value chain.
Interview by Scott Ertz of F5 Live: Refreshing Technology.
Scott Ertz is a seasoned media professional whose dynamic presence spans broadcasting, journalism, and tech storytelling. As Editor-in-Chief of PLUGHITZ Live, he leads a multimedia platform that blends insightful reporting with engaging live coverage of major industry events. He's best known as the host of F5 Live: Refreshing Technology, a long-running show that demystifies emerging tech trends with clarity and charisma, and Piltch Point, where he collaborates with Avram Piltch to spotlight cutting-edge innovations.
Scott's media journey began with a passion for connecting audiences to the pulse of technology. His work has taken him behind the scenes at CES, Collision Conference, and FIRST Robotics events, where he's interviewed industry leaders and captured the cultural impact of tech in real time. His on-camera style is both approachable and informed, making complex topics accessible to viewers across platforms.
Beyond hosting, Scott is a developer and producer, shaping the technical backbone of PLUGHITZ Corporation's properties. His storytelling is rooted in authenticity, whether he's scripting historical segments or crafting social media narratives. With a background in gaming culture and community engagement, Scott brings a unique blend of nostalgia, innovation, and journalistic integrity to every broadcast. His voice is one of curiosity, connection, and creative leadership.
