Automotive: BASF expands engineering plastics portfolio with PCR/PET grades; Covestro’s PC grade for Lexus produced using in-mould coating

German chemical firm BASF says it is expanding its portfolio of engineering plastics with new Ultradur grades designed to help automotive manufacturers and suppliers increase the recycled content of their products while meeting demanding technical requirements. 

The new portfolio includes glass fibre-reinforced PBT/PET compounds containing up to 30% post-consumer recycled content, combining sustainability with technical performance.

The new Ultradur RC1 grades have been developed to match the properties of conventional grades based on virgin raw materials as closely as possible. The designation RC1 stands for the use of post-consumer recycled (PCR) materials, with the RC1 products based on PCR-PET sourced from packaging waste not competing with established bottle-to-bottle recycling streams and is often used for energy recovery instead.

The grades have been specifically developed for structural automotive components. Typical applications include brackets, housings, structural parts, connectors, and other engineering components where both high mechanical performance and sustainability targets must be achieved. The portfolio comprises variants with different reinforcement levels to meet a broad range of application requirements.

In addition to increasing recycled content, the new products can contribute to reducing companies’ Scope 3.1 emissions. At the same time, they can support OEMs and suppliers in meeting evolving regulatory requirements regarding recycled content in plastic components.

Meanwhile in other news, Covestro Japan has announced the adoption of Makroblend UT235M (PC blends) as the substrate material for a large exterior part (luggage panel) on the Lexus ES, now in series production. The component is manufactured by Toyoda Gosei using an IMC process.

The adoption of this PC blend for an IMC process involves partners, and also where Covestro bridges laboratory and industrial scale development for series production.

IMC combines injection moulding and coating in a single, integrated process. By eliminating conventional post-painting steps, IMC contributes to reducing CO2 emissions while delivering outstanding Class A surface quality. The exceptional surface quality enables a seamless visual integration with adjacent glass, creating a refined, premium exterior appearance.

Makroblend UT235M is a PC blend commonly used in exterior applications where low linear thermal expansion and dimensional stability are important. For this application, the grade was selected to meet product requirements for exterior appearance, dimensional stability, and durability on the luggage panel. The grade is also compatible with the IMC coating system, supporting coating adhesion and the targeted surface finish in series production.

In the role of an IMC solution provider, Covestro says it collaborates across the value chain to advance adoption and scale up of in-mould coating in Japan.

Local support covers the complete process from application development to daily technical assistance. IMC evaluation capabilities are installed at the Covestro Japan site to verify under near production conditions and enable timely decisions with partners.

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