Emergence of low-cost plastic materials
The automotive industry across BRIC nations of Brazil, Russia, India and China has seen tremendous growth over the past decade led by rising incomes and availability of affordable vehicle financing options. This has bolstered the demand for mass-market vehicles which need to be efficiently manufactured at low costs. While initial growth was met through increased metal component usage, recent years have seen a strategic shift towards adoption of engineering plastics to substitute metal parts. The primary rationale behind this shift is the significant cost savings that plastic components provide compared to metal parts owing to their lighter weight and lower material costs.
All major automakers operating in BRIC markets have significantly ramped up their investments in plastic molding facilities, R&D of new plastic formulations and developing local plastic supply chains. Original Equipment Manufacturers (OEMs) like Suzuki, Hyundai, Renault-Nissan and Global OEMs who locally manufacture in these countries are at the forefront of driving this transition. Recent statistics indicate plastics now account for 10-15% of a vehicle’s total weight compared to just 5% a decade ago. This shift has been enabled by advances in plastic material design that have improved properties like heat resistance, impact strength and surface finish standards.
Exterior body panels see increased plastic usage
On the exterior of vehicles, composite plastic body panels are increasingly replacing steel for various body parts. Prominent examples include front-end modules, hoods, fenders, tailgates and door panels which were traditionally made of steel or aluminum. Stats indicate over 30% of an average BRIC-Market car’s exterior parts are now plastic compared to just 10% five years ago. Key factors driving this are the 10-15% weight savings that plastics provide over metal as well as superior design flexibility in complex shapes. The weight savings directly improve fuel efficiency which is a critical decision factor for the price-sensitive BRIC consumer.
Another advantage is plastics allow complex single-shot molding of integrated parts versus multiple welded steel stampings. This simplifies assembly and reduces manufacturing costs. With latest long glass fiber reinforced plastics, properties rival and even surpass mild steel sheets used previously. Plastic materials which were not suitable some years ago have advanced significantly to meet all performance needs under real world operating conditions in these markets. Major global resin suppliers like BASF, Covestro, DuPont, DSM, LG Chem, SABIC etc have established dedicated R&D/production sites in BRIC nations to tap this growing demand base.
Under-hood components switch to engineering plastics
A majority of non-structural under-hood components like intake manifolds, covers, brackets have transitioned from die-cast metals to engineered plastics over the last decade. Recent data shows plastics penetration here averages 50% now compared to just 25% five years ago. Materials like polyamides, polyesters, and reaction injection molded urethanes are favored for their heat resistance, strength over a wide temperature range and design flexibility.
Key factors like eliminating 6-8 welded joints with a single plastic part help simplify assembly. Plastic parts also eliminate treatment required for corroded steel or aluminum after years of combustion exposure. Material cost savings of over 15-20% along with weight reductions for these parts also improve overall vehicle efficiency. Engine covers made from thin-wall plastic composites shed over 2kg compared to die-cast aluminum counterparts. All these advantages have automakers aggressively pursuing new plastic component applications in this area each year.
Interiors leverage multifunctional plastics
vehicle interiors are also undergoing rapid transformation towards plastics. Dashboard assemblies, door panels, consoles which have traditionally used wood, vinyl or leather surfaces are increasingly adopting integrated functional plastic substrates. Technologies like in-mold decoration allow realistic textures and finishes to be molded-in without additional painting/layering processes.
This has changed the way interiors are designed and manufactured. Complex multi-material and multi-color assemblies can now be molded in one-shot, eliminating many assembly steps and yielding significant quality improvements. Weight savings of 10-15% versus conventional designs are also achieved. Another major trend is functional integration, with features like air-vent rings, logo emblems, speakers being directly molded into plastic substrates versus separately assembled. This simplifies interior ergonomics, improves ruggedness versus layers of different materials joined together.
Statistics show plastics usages in BRIC vehicle interiors has increased from 40% to over 55% in the past five years as OEMs and suppliers rapidly adopt new technologies. Meanwhile plastics with enhanced soft-touch and aesthetics rival traditional premium surface materials at a fraction of the cost. This has upended traditional approaches to target the price-sensitive yet quality-conscious BRIC consumer. Widespread use of integrated plastics cockpits may eventually expand to higher-end BRIC vehicle segments as well.
Sustained future growth predicted
All indications point towards further increased plastics usage over the coming decade across BRIC automotive markets. While current levels already surpass global averages, projections see ratios potentially exceeding 65% of total vehicle weight. This massive ongoing transition perfectly aligns with needs of automating BRIC manufacturers for low-cost automation-friendly materials. It also responds to evolving consumer preferences for bolder exterior designs, premium interiors and efficiency without compromising performance or build quality.
Sustained long-term growth in these nations will maintain new vehicle demand at current rates of 5-8% annually. A burgeoning indigenous automotive supplier ecosystem focused on plastics demonstrates rising capabilities to support OEM production plans. With global suppliers expanding local R&D/manufacturing footprints here proactively, automakers will steadily introduce more innovative new plastic applications that change automotive paradigms. Above all, plastics potential in these key markets remains untapped, ensuring many more new frontiers open up over the next decade and beyond.
