Polymers & Plastics in Automotive & Recreational Vehicles

A person drops a cell phone on the sidewalk. Exponent studies the strength and fracture of glass to improve screen technologies.

Case study

Clear as Glass: Understanding Strength and Fracture

Electronics

Consumer Products

Materials and Corrosion Engineering

Polymer Science and Materials Chemistry

Mechanical Engineering

How does Exponent help automotive manufacturers safely advance polymers and plastics technologies used in their vehicle manufacturing processes?

Today's consumers are enthusiastic about pushing the bounds of next-gen automotive and recreational technology — but automotive innovators must balance performance with consumer safety, environmental impact, and regulatory compliance.

Many components within automobiles are made from plastics, and 70% of those plastics are made from polypropylene, polyurethane, and PVC. Polymers are used for numerous exterior, interior, and under-the-hood applications — from door handles, upholstery, and dashboards to fuel systems, air conditioning, and automotive thermal management. These high-performing polymers are heavily regulated in the automotive industry and require careful polymer science and materials engineering considerations throughout the entire product lifecycle.

Exponent's multidisciplinary teams have deep expertise in materials; organic and inorganic chemistry; macromolecular, surface and polymer science; and a variety of products and manufacturing systems as well as vehicle engineering, industrial hygiene, and biomechanics and human factors.

For more than fifty years, our teams have led the consulting industry in performing failure analyses of all types of products and materials. We apply this knowledge to solve future challenges — including issues of intellectual property, warranties, and product recall.

We assist automotive industry manufacturers in pre- and post-market activities, including:

Materials recommendation and selection.

Materials development, qualification, standardization.
Verification and validation of plastics and other materials used in automotive production.
Failure and root cause analysis arising from pre- and post-development incidents.
Warranty, product recall, and litigations support.

Capabilities and Services

Exponent's engineers and scientists provide technical expertise for the design, analysis, manufacturing, testing, and failure investigation of composite structures and advanced composite materials in many structural applications for the auto industry. We conduct rigorous laboratory tests to determine the strength and failure rate of automotive composite materials and help our clients understand how to apply these innovative technologies to optimize manufacturing, production costs, as well as safety. Our ecological and environmental teams consult on regulations regarding composite disposal and recycling and can help manufacturers develop compliant product stewardship programs.
Exponent delivers deep understanding of the chemistry, physical properties, and mechanical behavior of polymeric materials, including rubbers, elastomers, adhesives, and rigid plastics. We assist clients with durability assessments, materials specifications, formulation, end-use testing, product safety evaluations, and failure analysis in both proactive and reactive programs in the automotive industry.
When polymer products crack, expand, break, shatter, or fail to perform as expected, automotive manufacturers turn to Exponent for answers. Our multidisciplinary approach enables us to strategically evaluate and analyze the manner in which a polymer may have fractured while in service, as well as degradation and stability in additive manufacturing, to help our clients improve material resilience and durability.
Automotive trends and customer demand drive the need for new and improved paint technologies. Whether testing new paint materials, examining application methods, or analyzing product failure — Exponent provides expertise in all aspects of liquid paints, powder coatings, functional coatings, and thin films for the automotive industry. We consult on issues of formulation, adhesion, and physical properties; application processes; regulatory compliance; and durability.
We consult in the areas of fuel, oil, and lubricant formulations for automotive and industrial applications, paints and coatings, and industrial and specialty chemicals, including fluorinated substances (PFAS). We leverage our 50+ years of experience in automotive manufacturing consulting and failure analysis to help clients determine the source and potential impacts of chemical contamination in a range of products, and we provide research and support for intellectual property disputes, including trade secret and patent litigation.
Exponent's experts have extensive experience in studying and advising clients on the structure-property relationships and processing of polymeric systems. We consult on the development, formulation, scale-up, quality testing, and large-scale industrial manufacturing of polymers and plastics, and we assist auto manufacturing clients in all stages of the product lifecycle — from product development to end-use evaluation and long-term field performance.
Silicon and synthetic sealants failures in automobile production can lead to premature corrosion, equipment failure, and harmful accidents. Likewise, unwanted silicone attachment to a substrate surface can severely affect bonding and coating processes. Exponent multidisciplinary experts provide consultation throughout every stage of the vehicle manufacturing process — from product design and development to end-use — helping you understand and mitigate challenges regarding sealants.
Exponent leads the automotive consulting industry in helping clients make informed decisions regarding the development and application of lithium-ion batteries. Our capabilities span the entire product lifecycle, including battery design reviews, battery safety and storage, quality safety assessments, risk assessments and corrective actions, battery safety and recall support, battery supply chain services, battery recycling, and product stewardship initiatives. Our experts use Exponent's state-of-the-art testing and disassembly laboratory services for the design, testing, and recall assessments and recycling of all lithium-ion battery technology.
Seat coverings, seatbelts, insulation, high-tensile airbags, and different types of hoses and components — all use automotive textiles that are subject to rigorous quality and performance standards. Exponent's multidisciplinary teams have a breadth of vehicle industry and polymer expertise to help you solve any challenge related to vehicles textiles made of nylon, vinyl, and engineered composites.
Our automotive consultants in Polymer Science and Materials Chemistry offer the following services:
- Materials recommendations, selections, and development
- Independent design evaluations
- Product testing and quality compliance
- Regulatory compliance support (U.S. and international)
- Third-party auditing, including engineering audits, vendor evaluation, and manufacturing line failure analysis
- Patent protection and infringement evaluations
- Product warranty and recall support
- Risk and failure analysis
- Insurance, environmental, or health claims investigations
- Litigation support and expert witness testimony

Our Capabilities Are Unparalleled

With expertise in over 90 disciplines and hundreds of capabilities, tools, and methodologies — we get to the root of even the most complex challenges and give you the objective answers you need.

A worker pours a bag of polymer beads into a manufacturing machine. Exponent provides engineering expertise for polymers and plastics.

Related Expertise

Experts

Our global and comprehensive expertise across industries gives us a deep understanding of current challenges, best industry practices, and the implications of emerging technologies.