What Automotive Parts Can Be Produced Using Plastic Materials?

Plastics now play a major role in modern vehicles, not only for trim but for many internal, external, structural and under-bonnet parts. Advances in materials and injection moulding mean plastics can meet strength, durability, safety and cost demands.

To discuss further, Ansini, specialists plastic manufacturers, outline the most common plastics used in automotive manufacturing, the parts made from them, the benefits they offer and why many manufacturers choose plastic over traditional materials.

Common plastic materials used in automobiles

One of the main plastics used in vehicles is polypropylene, which is lightweight, chemically resistant, and flexible. It is mostly used for exterior parts like bumpers, battery housings, and reservoirs as well as some interior trim. The dashboards, interior trims, consoles and covers of a vehicle are usually made up of Acrylonitrile Butadiene Styrene (ABS) as it is tough, impact-resistant and offers a good surface finish.

Polyamides are used for under-the-bonnet components, engine parts, brackets and structural elements as they offer high strength, heat resistance and chemical and wear resistance, whilst polycarbonate (PC) and PC-blends are ideal for headlight lenses, light housings, transparent covers and windows as they offer optical clarity and UV and weather resistance.

Thermoplastic elastomers and soft plastics are known for their flexibility and offer good sealing and vibration damping, which means they are used for seals, gaskets, interiors, soft-touch parts, insulation and cable housings. There are also reinforced or composite plastics that are used for parts that need extra strength, rigidity or heat and chemical resistance.

What car parts are commonly made from plastic?

Plastic is used in the interior and exterior of a vehicle. Inside a car, you are likely to find it in the dashboards, instrument panels, centre consoles, door panels, interior trim, vents, dashboard covers, gloveboxes and control buttons. Outside the car you are likely to find plastic in the bumpers, grilles, mirror housings, light housings, trim, mudguards and exterior mouldings.

Plastic will also be found when you lift the bonnet as part of the air-intake manifolds, battery housings, fluid reservoirs, air-filter housings, engine covers, fuse-box housings and wiring harness clips or brackets.

The structural safety and finishing components of the vehicle are also likely to be made from plastic, including the seat frames and mechanism components, fasteners, clips, trim panels, seals, gaskets, internal structural supports, under-body shields and insulation elements.

Benefits of plastic parts in automotive manufacturing

Plastic is a lightweight option that offers optimal fuel and energy efficiency. It is also incredibly cost-effective as injection-moulding will allow high-volume production at low per-part cost.

Another important benefit of plastic is its design flexibility, as it can be moulded into a range of complex shapes and can integrate clips, hinges, or mounting points to create ergonomic or aerodynamic designs that traditional materials can struggle with.

It is also resistant to corrosion, chemicals and weather, making it ideal for any parts that are exposed to the elements. As flexible plastics and elastomers help to damp vibration and reduce noise, this can improve the cabin comfort of a vehicle as well as the durability of any moving parts.

Plastic plays a part in safety and regulatory compliance, as these modern materials can be engineered to meet the strictest safety standards.

There are also several aesthetic and finishing advantages, as there is almost no limit to the finishes, colours or textures that plastic can achieve. Many plastics that are used today are also recyclable or can incorporate recycled materials, making them a more sustainable option.

Why manufacturers choose plastic

Plastic is now a popular choice as it offers a good balance between mechanical performance and manufacturability. It is compliant with a wide range of regulatory and safety standards and is adaptable for all vehicle types, whether it is a compact car, a truck, or an EV.

There is also an improved level of production scalability as plastic is ideal for large-volume manufacturing, with consistent quality, reduced waste and cheaper unit costs.

Plastic materials and injection-moulding are fundamental to modern automotive manufacturing. As vehicles evolve, plastic will remain an essential part of how cars are built, thanks to its versatility, sustainability, and affordability.