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John Mellor's<br />

GoAuto<br />

By DAVID HASSALL<br />

A WORLD plastics expert believes that<br />

Australian car-makers and parts manufacturers<br />

will need to embrace new technology in order<br />

to meet future fuel consumption and design<br />

requirements.<br />

Sabic Innovative Plastics, a Saudi Arabian<br />

company that last year took over GE Plastics,<br />

has developed a lightweight alternative to<br />

automotive glass as well as a plastic<br />

material that recycles plastic bottles<br />

but does not possess the reduced properties of<br />

regular recycled plastic.<br />

Sabic’s global technical manager for body<br />

panels and glazing Frank Mooijman has told<br />

GoAuto that these new developments would<br />

revolutionise the design and production of<br />

headlights, front fenders, rear quarter windows,<br />

tailgates and panoramic roofs in particular.<br />

A Dutch-based engineer, Mr Mooijman also<br />

previewed a new style of steering wheel made<br />

entirely without metal that could be moulded<br />

into any shape a designer desired. He expects<br />

such injection-moulded steering wheels will<br />

be in production within two years.<br />

Visiting Australia earlier this month,<br />

Mr Mooijman demonstrated Sabic’s latest<br />

developments to OEMs and suppliers,<br />

underscoring the benefits of plastic in terms<br />

of design flexibility and reduced weight.<br />

Half a century ago, GE invented Lexan,<br />

a bulletproof polycarbonate material that<br />

protects the eyes of racing drivers and<br />

motorcyclists around the world, and one of<br />

Sabic’s new products is Lexan glazing that<br />

Mr Mooijman said has “stormed the market”.<br />

Lexan glazing is half the weight of glass<br />

and, although also twice as expensive, would<br />

Green Green issues in the auto world<br />

SUBSCRIBE FREE: www.mellor.net<br />

Green A p r i l 16, 2008 Page 23<br />

Custom Fleet<br />

Part of GE Commercial Finance<br />

GoAuto Green is brought<br />

to you by Custom Fleet<br />

Plastic fantastic<br />

New materials and<br />

technology are changing<br />

the automotive industry<br />

Custom Fleet<br />

Part of GE Commercial Finance<br />

save up to 5kg for a Holden Commodore rear<br />

window.<br />

In the case of a panoramic roof on an SUV<br />

or people-mover, as on the latest Europeanmarket<br />

Opel Zafira, the weight reduces from<br />

about 40kg to 20kg and greatly lowers the<br />

vehicle’s centre of gravity.<br />

“I think fuel consumption pressure will<br />

come here (to Australia), and if that starts<br />

to become a pressure, then look at all the<br />

parts that can save you weight,” said Mr<br />

Mooijman.<br />

“Really, everyone should be looking at<br />

glazing. With the current technology, it’s a<br />

no-brainer. You should look at opportunities<br />

there to take your weight out.”<br />

Sabic has developed defroster technology<br />

to enable Lexan glazing to be used for rear<br />

windows, but it remains too flexible to be<br />

used on wind-up side windows and is not<br />

legally permitted for windscreens, which<br />

must be made of glass.<br />

However, Sabic hopes that legislation will<br />

change in the future and in the meantime is<br />

working on new hard-coating so that plastic<br />

windscreens of the future will be sufficiently<br />

“We listen to your needs.<br />

Then we create tailor-made solutions.”<br />

To find out more, call Custom Fleet, the fleet management experts on 1800 812 681.<br />

Opel Zafira uses lightweight Lexan<br />

material (left) in its modular roof<br />

scratch-resistant to wipers.<br />

Lexan rear glass is being used on four<br />

production models globally, including the<br />

innovative wraparound “extra window” that<br />

brings a unique styling element to the tail of<br />

the British-built Honda Civic hatchback, as<br />

seen on the local-market Civic Type R.<br />

The same material enabled Volkswagenowned<br />

Seat to make its five-door Leon<br />

hatchback look like a two-door coupe by<br />

having a non-glass rear quarter window with a<br />

built-in recessed hand-grip that provides access<br />

to the hidden door handles, so the rear doors<br />

do not have obtrusive handles. The complex<br />

shape exceeded the limitations of glass.<br />

“This is really new,” said Mr Mooijman.<br />

“Trains and trucks are a little further ahead<br />

because the requirements are different to<br />

automotive, where scratch resistance is really<br />

important. So there are only four (cars) on the<br />

market, but many more to come.<br />

“Traditionally, our contact is with<br />

engineers, but we do more and more with<br />

stylists because they drive new developments<br />

in the automotive industry.<br />

Continued next page

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