The largest polycarbonate roof module to date
The largest polycarbonate roof module in automotive history, offering superior surface quality and significant weight reduction
Shanghai – The new "smart fortwo" is redefining urban mobility with its eco-friendly design, low fuel consumption, and minimal carbon dioxide emissions. A standout feature of this model is its lightweight roof made from Makrolon® AG2677, a polycarbonate material developed by Bayer MaterialScience. This roof module, measuring approximately 1.2 square meters, is the largest of its kind ever produced for automotive assembly lines. “This achievement marks a major milestone in the use of polycarbonate in vehicle roofs,†said Dr. Sven Gestermann, Key Account Manager at Bayer MaterialScience. The module was manufactured by Webasto AG, a leading global supplier of roof systems, based in Stockdorf near Munich.
Webasto used a two-component injection compression molding process on a rotary platen machine to produce the roof. The transparent shell was made using Makrolon® AG2677, while the structural frame was crafted with Bayblend® DP T95 MF. A special black coating, composed of PC and ABS, was also developed for the application. This hybrid material helps reduce stress and distortion, ensuring high-quality surface finish. “Despite its large size, the roof maintains very low internal stress and minimal deformation, which is crucial for maintaining optical clarity and aesthetic appeal,†explained Gestermann.
The plastic roof is 40% lighter than a traditional glass equivalent, significantly improving fuel efficiency and reducing the car’s center of gravity, enhancing driving dynamics. Detlev Penczek, who led the panoramic roof development, emphasized that weight reduction, design flexibility, and integration potential were key factors in choosing polycarbonate. “This material allows us to create more functional and aesthetically pleasing designs,†he noted.
Bayer and Webasto have collaborated extensively on polycarbonate roof solutions. “Working with Bayer has given us access to their deep expertise in materials, processing, and analytics,†said Martin Pollak, Head of Roof Module Development at Webasto. Their support spans the entire production chain, from simulation and rheological analysis to mold development and line setup.
Looking ahead, Gestermann believes there is still untapped potential in larger polycarbonate roofs. “With current materials and advanced molding technology, we can easily produce low-stress roofs up to 1.7 square meters,†he said. He also envisions future designs incorporating features like spoilers, lights, roof rails, and water management systems. “By leveraging the full potential of Makrolon® AG2677 and Bayblend® DP T95 MF, we aim to reduce costs and simplify assembly,†he added.
About Bayer MaterialScience:
Bayer MaterialScience is one of the world's leading producers of polymer materials, with annual sales of €10.16 billion in 2006 (excluding HC Stark and Wolff Walsrode). The company focuses on high-tech polymer solutions for industries such as automotive, electronics, construction, and consumer goods. With over 30 production sites and 14,900 employees worldwide, Bayer MaterialScience is part of the Bayer Group, dedicated to innovation and sustainability in everyday applications.
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