Cars have changed significantly in the last 20 years. They are now much more complex as many items that were formerly available, if at all, on only the most expensive models have now become standard. Environmental considerations and recyclability are also now important issues. These changes have been reflected in the materials from which cars are made. Although steel and cast iron are, and will remain, important, much more use is now made of other materials including plastics.

This report examines the application of plastics in European cars in the middle of the year 2000. It evaluates the changes in use and considers possible developments over the next decade.

Following discussion of the automotive market, materials, semi-finished products and processing techniques are reviewed. The properties of the major classes of thermoplastic and thermoset materials are described with reference to general areas of application in cars and the major suppliers. The different types of reinforcement and core material are reviewed as a range of performance targets may be met by the same resin by utilising different types and quantities of reinforcement.

The use of plastics for specific components is examined with discussion under the headings: Bodywork, chassis and glazing, Interior components, Under the bonnet and Electrical applications and lighting. Comparison is made between competitive materials and examples of commercial application are included.

The regulations applying to the construction and manufacture of cars, and which affect the choice of plastics as automotive materials, are discussed: fuel economy, tailpipe emission standards, fuel systems emission standards, pedestrian safety, noise, recycling and control of emission during manufacture.

Estimates are presented for current plastics usage in European cars with forecasts to 2008. Company profiles for more than 50 major European automotive suppliers complete the report. The report will provide useful information to all involved in the production process: designers, materials suppliers, processors, fabricators and assemblers.About the author

Ian Helps, B.A., M. Phil., attended the Universities of Oxford and London, where he read economics. After extensive industrial experience he spent twenty years working at the National Economic Development Office (NEDO). From 1981 to 1987 he was Secretary of the Economic Development Committee for Plastics Processing. Since leaving NEDO he has worked as a freelance consultant, mainly in the plastics and rubber industries, specialising in automotive and public transport applications of polymers. Published reports include analyses of the European markets for resin transfer moulding, pultrusion, and filament winding, and of the markets for plastics additives. He is a fellow of the Royal Statistical Society and a member of the Institute of Materials and the Plastics Consultancy Network.