Development of recyclable self-reinforced polypropylene parts for automotive applications

Self-Reinforced Polypropylene (SRPP) offers competitive mechanical properties, higher recyclability and reduced weight compared to glass fibre-reinforced PP, making it attractive to the automotive industry. The technologies required to produce finished automotive components from SRPP have been developed during a UK-based project, called RECYCLE and supported by the UK government. Forming processes and associated tooling systems have been developed based on matched tool stamping. Suitable joining techniques have been identified, including adhesive bonding and welding and all-PP sandwich panels have been produced and tested. Automotive finishes, such as exterior paint and interior fabrics, have been applied successfully. The technology has been demonstrated in two automotive case studies - an exterior panel for the Lotus Elise and an interior cover panel. Significant weight savings have been identified compared to current production parts and the technology has been shown to be sustainable from environmental, social and economic viewpoints.