Stockdorf/Munich. – Car makers’ requirements in terms of the design, quality and variability of vehicle roofs have been growing continuously for many years now. Particularly in view of the increasing variety of segments and models, more and more complicated and demanding solutions are being called for. This means suppliers have to offer the highest levels of expertise and flexibility. By using innovative material technologies such as polycarbonate, Webasto is once again underlining its leading position as a developer and producer of top-end systems for the automotive industry. At the same time, the company is gearing up today for the requirements of the future.

The Webasto louvred roof for the current A and B Class models from Mercedes Benz was the successful first use of polycarbonate in an automotive roof system. The new technology clearly shows its advantages compared to the popular steel louvred roof of the previous model: The weight saving of about 3.5 kilograms represents a significant reduction for a single component in body production. Passengers are particularly appreciative of the transparency of the louvers and the associated improved feeling of space.

From Webasto’s perspective, the particular material properties of polycarbonate make it a material with great future potential for roof elements. This is because in addition to its transparency, it above all offers high resistance to external influences such as stone impact and does not shatter in the event of a crash. As a result, it is set to be used increasingly in future. Another positive aspect is that polycarbonate can be processed using the injection moulding process, thereby enabling a great variety of three-dimensional component designs to be achieved. As a result, roof modules are set to benefit from previously unknown levels of design freedom in the future.

Webasto has installed its own production line for products referred to as “polycarbonate glazing elements” at its plant in Schierling near Regensburg. Through this investment, Webasto is underlining its commitment to achieving technological leadership in this sector. The injection moulding machine, representing an investment of several million Euros, will in future be used for manufacturing polycarbonate roof elements in a two-component injection moulding process. The machine is impressive not only for its sheer size (26 metres long, up to 5 metres tall and weighing 300 tonnes) and force (die locking force 2700 tonnes), but also for its range of functions. The specially produced stamping die is capable of using various processes such as in-mould pressing, parallel stamping and expansion stamping which would otherwise have had to be performed by several different machines. Directly following this, the glazing elements are coated in a separate machine. This lends them important additional properties such as scratch and weather resistance. The glazing elements can be assembled directly after this working step.

The machine is currently at the trial stage, although the first ambitious vehicle roof projects will be implemented using it within only a few years. As a result, the future of new material technologies has already dawned.