Bring back the steel? The growth of plastics in automotive applications

The development of plastics has evolved from the use of natural materials to the use of chemically modified natural materials and, finally, to completely man-made molecules. Plastics continue to improve, to afford flexibility, high-impact, and strength. In automotive applications, plastics have increased in utilization to comprise approximately 10% of the total vehicle weight. They offer increased ductility, freedom from corrosion, and increased styling capability. Although plastics have had a remarkable impact on our culture, it is obvious that there is a price to be paid for their use. Plastics are almost too good, as they are durable when processed correctly, but easily damaged when utilized in the incorrect application. Plastics also degrade very slowly, making recycling mandatory. And finally, while plastics consume only 4% of the world’s oil production (petroleum is the raw material that is chemically altered to form commercial plastics), their cost hinges on the cost of petroleum. As petroleum prices increase, so too will the cost of plastic. In 2004, the higher price of plastic forced many plastic manufacturers out of business, and forced many automotive suppliers to look into alternative replacements. With publications such as USA Today reporting that current oil reserves will only last 40 years, scientists continue to seek cheaper alternatives to plastic. This article summarizes the history of commercial plastic development, with a focus on utilization of the materials in automotive applications. Damage criteria of plastic components, namely scratch, oxidative degradation, and impact, are discussed in relation to coatings and processing robustness. Environmental regulations, particularly in relation to recycling mandates, are explained. And finally, trends in alternative material development, including bioplastics, films, ceramic coatings, and nano-composites; are formulated. Presented at the 83rd Annual Meeting of the Federation of Societies for Coatings Technology, November 6–9, 2005 in Las Vegas, NV.