KOLLEKT brings together FORVIA HELLA as coordinator alongside partners BMW, Covestro, Geba, Fraunhofer IEM, Fraunhofer UMSICHT, the University of Paderborn, Hamm-Lippstadt University of Applied Sciences, the Helmholtz-Zentrum Dresden-Rossendorf (HZDR), and SW Maschinenservice. The project runs from June 2026 to May 2029, with a total BMFTR funding volume of €4.371 million including project lump sums.

From Headlamp to Tomorrow's Resource

The automotive industry faces growing pressure from resource scarcity, supply security concerns, and tightening regulatory requirements — most notably the EU End-of-Life Vehicles (ELV) Regulation. Technological hurdles, cost pressure, and insufficient product recyclability have so far prevented efficient plastics cycles from becoming established at scale. KOLLEKT directly addresses this gap by placing "Design for Circularity" at its core — product design optimized for recyclability from the very beginning, complemented by four R-strategies: Repair, Re-Use, Remanufacture, and Recycle. KOLLEKT researches how future lighting components can be made repairable, reusable, and recyclable — and what production and logistics processes this requires.

Covestro's Role: Materials That Enable Circularity

As a key materials partner in KOLLEKT, Covestro contributes its deep expertise in high-performance polymers and sustainable material solutions — working across the full circular value chain, from supporting circular product design and material concepts through to the evaluation of recycling pathways for polycarbonate. Covestro's Makrolon®, Bayblend® and Apec® materials are among the most widely used plastics in automotive lighting applications, and bringing these materials back into high-quality use cycles is central to the project's ambition. Covestro's involvement ensures that material properties, recyclate quality, and end-of-life behavior are fully considered from the design stage onward — a prerequisite for true circularity, and a direct expression of Covestro's vision of a fully circular economy.

"KOLLEKT is a prime example of how we create value together with our customers and partners — going beyond material supply to co-designing solutions from the very beginning," says Monique Buch, Chief Commercial Officer at Covestro. "By aligning early across the value chain with BMW, FORVIA HELLA and other partners, we can embed circularity directly into product development. That is what true co-creation looks like—and how we turn sustainability ambitions into tangible outcomes.”

Intelligent Dismantling and Digital Twins

A flexible, AI-powered robotic dismantling cell is central to KOLLEKT's technical approach. Using digital product twins and AI-based data processing, the project establishes the foundation for reuse and recycling at industrial scale — enabling precise, largely automated, and material-pure disassembly. Networked data exchange integrates material, product, and process information in real time, creating a transparent, traceable circular ecosystem.

Building on Proven Foundations

KOLLEKT builds directly on its predecessor project NALYSES, successfully completed in 2026, and advances its findings into a comprehensive, end-to-end circular value creation model. Early involvement of SMEs, industry associations, and networks — alongside conferences, academic teaching, and publications — ensures that results can be scaled and transferred to other sectors beyond automotive lighting, including electrical and electronics applications.

Advancing Circular Economy Goals

KOLLEKT aligns directly with Covestro's strategic commitment to the circular economy. Covestro continues to expand its portfolio of circular solutions — including its post-consumer recycled Circular Intelligence (CQ) product families like the R, RV and RP material lines. Notably, RV and RP product lines address post-consumer car2car recycling, featuring recycled end-of-life vehicle materials such as headlamps, with third-party certification. The insights generated by KOLLEKT will contribute to meeting EU ELV recycling targets toward 2032 and support automotive manufacturers in fulfilling expected recycled content quotas — without compromising performance or quality. Through its global production and supply network, Covestro supports decarbonization and resource circularity in mobility, truly elevating materials into solutions that matter.

"KOLLEKT is a concrete step toward closing the loop on high-performance polycarbonate in automotive applications," says Guido Naberfeld, Head of Sales and Market Development Mobility at Covestro. “By combining Design for Circularity with advanced recycling technologies and digital traceability, we are demonstrating that sustainability and material performance are not a trade-off. This is how Covestro contributes to meeting the EU's ELV targets and helps the entire automotive value chain transition to a truly circular model.”

The agreement marks a significant evolution in the two companies’ relationship – moving beyond traditional supply towards collaboration across the value chain, driven by a shared conviction that the future of mobility, energy and intelligent systems demands deep co-innovation. For Covestro, the partnership directly supports its “Sustainable Future” strategy by advancing innovations that enable circular solutions and drive growth in industries where material performance is becoming an increasingly important source of competitive advantage.

“At Covestro, we believe in the power of material science and collaboration to drive industry transformation – and this partnership with BYD is a strong example of that," said Lily Wang, President of Engineering Plastics at Covestro. "BYD's expanding portfolio represents some of the most exciting and demanding material challenges of our time, and that is exactly where Covestro’s depth of expertise becomes most valuable. We look forward to translating that expertise into tangible solutions together with BYD.”

“Covestro has proven itself as a trusted material innovation partner, and this agreement reflects our confidence in taking that relationship to a new level,” said Head of Materials, BYD. “As we continue to push the boundaries of what is possible in future mobility and beyond, we look forward to co-innovating with Covestro to develop the advanced material solutions that will redefine future industries and accelerate our global ambitions.”

Material expertise complementing BYD's cutting-edge applications

Under the MoU, the two companies will deepen their collaboration across new energy vehicles, power batteries, public transportation, energy storage, and new technology applications. The partnership will include joint innovation initiatives, technology co-development and strategic investment opportunities.

Covestro will provide dedicated R&D resources to co-develop new material technologies, volume supply security, early access to new material innovations and customized technical support. BYD in turn commits to proactively engaging Covestro in new projects and technology roadmaps across its entire business portfolio.

Covestro’s world-class material expertise in polycarbonate and polyurethane solutions, backed by decades of experience in automotive and electronics application, complements BYD’s key application areas:

• New energy vehicles: Proven material solutions in lighting, premium interior and exterior, and intelligent electronic components, delivering both aesthetic and functional value for smart mobility.
• Power batteries & energy storage: Lightweight, high-performance materials that balance safety, thermal management, and cost efficiency across EV and residential applications.
• Next-generation technologies: High-performance polymer solutions engineered for extreme demands – combining lightweight construction, structural integrity, thermal and electrical management, and durability to enable complex technology platforms of the future. 

Building a more sustainable industrial future

Beyond product co-development, the two companies are committed to advancing low-carbon and circular material solutions that reduce the environmental footprint of next-generation mobility, energy and intelligent systems. Covestro’s CQ (Circular Intelligence) labeled materials, made with at least 25 percent alternative raw materials, form a key part of this commitment.

With the acquisition, Covestro expands its production footprint for HDI derivatives and reaffirms its commitment in two important regions, while strengthening its ability to serve customers in the coatings and adhesives industry with greater flexibility and reliability.

HDI derivatives are essential building blocks for high-performance polyurethane coatings, adhesives and sealants. They are used in a broad range of applications, including automotive coatings, protective coatings for infrastructure, marine coatings, wood furniture, electronics and other demanding industrial applications.

“By adding these sites in Thailand and the US, we are strengthening our regional production capabilities and improving our ability to supply customers from locations close to them,” said Thomas Roemer, Head of the Business Entity Coatings and Adhesives at Covestro. “Reliable supply, regional availability and technical expertise are critical for our customers, especially in a challenging market environment. This acquisition helps us deliver even better on those needs.”

The two sites complement Covestro’s existing production network for HDI derivatives in major regions including Europe, Asia and North America. The additional capacities will further enhance Covestro’s ability to respond to customer demand and support long-term growth in high-performance and more sustainable coatings and adhesives applications.

“Strong customer relationships are built on trust, reliability and the ability to deliver value over time,” said Monique Buch, Chief Commercial Officer of Covestro. “This acquisition strengthens our position in a business where customers count on us for consistent quality, regional supply and application expertise.”

The acquisition follows Covestro’s earlier acquisition of the Resins & Functional Materials business from DSM and continued investments in organic growth, underlining the company’s commitment to the coatings and adhesives industry.

ISCC PLUS-certified chlorine from Covestro is produced by using electricity from renewable sources, supporting a more sustainable production process and contributing to lower greenhouse gas emissions.

As of January 2026, the entire CR production of ARLANXEO is based on ISCC PLUS-certified chlorine, marking an important milestone in the company’s sustainability journey and its commitment to a more sustainable value chain. 
This transition is resulting in an average reduction in global warming potential (GWP) of approximately 20% compared to 2025 levels¹, depending on the specific product grade.

“Integrating ISCC PLUS-certified materials into our production is a key step in reducing the environmental footprint of our CR rubber products,” said Niels van der Aar, Head of Sustainability at ARLANXEO. “It underlines our commitment to supporting customers with more sustainable material solutions while advancing transparency along the value chain by supplying corresponding product environmental footprint data for ARLANXEO’s entire CR product portfolio.” 
As a key chemical supplier to ARLANXEO, Covestro plays a crucial role in enabling this transition by supporting the availability of ISCC PLUS-certified chlorine.

“At Covestro, we support our customers in reducing emissions along the value chain by supplying more sustainable basic chemical raw materials from our multiple ISCC PLUS-certified production sites,” said Moritz Winterstein, Head of Trading Cluster Basic Chemicals EMEA at Covestro. “Our collaboration with ARLANXEO demonstrates how certified raw materials and renewable electricity can contribute to lowering the product environmental footprint of downstream applications and support customers in achieving their sustainability targets.”

The introduction of ISCC PLUS-certified feedstock, like ISCC PLUS Chlorine, strengthens the position of ARLANXEO as a leading supplier of more sustainable elastomer solutions, particularly for industries with ambitious climate targets, such as automotive, construction, industrial and adhesive applications.

In addition, ARLANXEO can also offer Baypren® Eco grades combining ISCC PLUS-certified chlorine and ISCC PLUS-certified butadiene, enabling further reductions¹ in environmental impact and supporting customers in achieving their sustainability targets without any compromise in performance.

_{¹ Relative changes in Global Warming Potential – GWP100 incl. biogenic [kg CO₂e] 
Example of the relative change of the Global Warming Potential (GWP100 incl. biogenic [kg CO₂e] for Baypren^® 116 M45 as from January 2026. In the graph also the Baypren^® Eco 116 M45 is added as Eco option. A full Product Environmental Footprint report is available upon request.}

The successful implementation exemplifies how “The Material Effect” elevates materials into solutions that matter. This was achieved through an innovative partnership between Toyota Motor Corporation, Toyota Motor Kyushu, INC., parts supplier Kojima Industries Corporation, and Covestro. Together, the four companies conducted comprehensive testing and evaluation to ensure the recycled material met all performance requirements without compromising quality standards.

Integrating high levels of post-consumer recycled content into visible premium interior parts has typically been a high technical hurdle - making use in such areas difficult with many resins - yet the Bayblend® resin used in the LEXUS ES demonstrates that this barrier can be overcome. This marks one of the first integrations of 35% post-consumer mechanically recycled content in visible components within a premium automotive segment.

Meeting Performance Standards 

By fusing premium materials with specialized expertise, Bayblend® T85X R35 CQ delivers on all specifications for multiple Lexus ES interior parts while incorporating post-consumer recycled content. The material delivers essential performance characteristics including durability, surface quality, dimensional stability, and processability while integrating seamlessly into existing manufacturing processes.

"This collaboration demonstrates that more sustainable materials can meet the required standards of premium automotive applications," said Fumihiro Togashi, Global Strategic Account Manager, Toyota Group at Covestro. “By working closely with Kojima Industries Corporation, Toyota Motor Corporation, and Toyota Motor Kyushu, INC. throughout the development process, we've proven that environmental responsibility and product excellence can go hand in hand.”

The material's versatility extends beyond pre-colored applications to paintable components, enabling use in both visible interior areas and exterior parts. Covestro ensures consistent quality and supply reliability by utilizing one of the most dependable post-consumer recycled sources in the plastics industry. The company's global production footprint further enhances cross-regional supply stability and provides capacity to support anticipated volume increases as more sustainable automotive materials gain broader market adoption.

Advancing Circular Economy Goals

This adoption aligns with the four companies' sustainability strategies. Covestro positions the circular economy as a strategic pillar and continues expanding related product families. Toyota Group leads industry initiatives in environmental stewardship and resource circularity. In parallel, Kojima Industries Corporation and Kojima Group drive sustainability across manufacturing and supply chains, supporting circular material use and responsible sourcing.

The partially recycled plastic solution supports fulfilling expected quotas related to the ELV Regulation, demonstrating how more sustainable materials can simultaneously meet performance and regulatory requirements in the automotive industry.

Looking Ahead

Covestro continues expanding its circular economy solutions through “The Material Effect” approach, including the recently launched "RV line”, part of the post-consumer recycled R series – featuring recycled end-of-life vehicle materials such as headlamps, with third-party certification. These developments address critical automotive industry challenges amid tightening environmental pressures and regulatory requirements.

The innovations will contribute to EU ELV recycling targets toward 2032. Through its global production and supply network, Covestro supports decarbonization and resource circularity in mobility while enabling automotive manufacturers to meet evolving regulations without compromising product quality - truly elevating materials into solutions that matter.

Marquardt, a leading supplier of smart mechatronic systems for automotive applications, set out to address this challenge with its concept car, “The Centum”. A key objective in The Centum project was to develop a door interior panel that maintained the visual and haptic properties of polyurethane (PU)-coated textile synthetics commonly used in automotive interiors, while enabling a dynamic color-changing responsive display to be invisibly embedded within the surface. This functionality supports emerging trends such as backlit surfaces and integrated control elements.

To realize this vision, Marquardt partnered with E Ink, a leader in advanced display technology known for durability, low energy consumption, and suitability for demanding environments. The challenge was to integrate the functional display into the interior design in a way that preserved the premium appearance and performance of coated synthetic surfaces, while allowing the display’s colors to remain clearly visible.

After evaluating multiple approaches, Marquardt approached Covestro to develop a suitable material solution. Covestro textile coating experts worked closely with both partners to develop a fully transparent film based on INSQIN^® waterborne PU technology, with Impranil^® DLC-F as the foundation. Impranil^® DLC-F is a waterborne polyurethane dispersion widely used in topcoats for automotive interior textile coatings. The result is a transparent coated synthetic that retains the premium texture of automotive textiles while allowing the display’s dynamic colors to be fully visible, fulfilling the demanding performance requirements of automotive interiors.

Felix Hake, Head of Innovation at Marquardt said: “With The Centum, we wanted to demonstrate how intelligent functions can be integrated into interior surfaces without compromising design or quality. Working with E Ink and Covestro allowed us to create a material solution that combines a premium tactile experience with responsive visual effects.”

Dr. Torsten Pohl, Global Head of Textile Coatings at Covestro added: “This project highlights the versatility of INSQIN^® PU technology and Impranil^® DLC-F. By developing a transparent, automotive-grade PU coated synthetic compatible with E Ink displays, we were able to support Marquardt in integrating dynamic functionality into familiar surface materials.”

Pete Valianatos, Senior Director, Strategic Initiatives & FPL Platform Management at E Ink, noted: “Our e-paper display technology is designed to deliver dynamic visual experiences with low power consumption, while maintaining the robustness required for demanding applications. Collaborating with Marquardt and Covestro has enabled us to demonstrate how E Ink displays can be integrated behind coated interior surfaces, allowing automotive designers to introduce adaptive color features without changing the established look and feel of premium materials.”

To see what this responsive functional surface looks like, visit Techtextil 2026, held in Frankfurt between April 21 and 24. A door panel demonstrator will be on display at the Covestro booth C79 in hall 11.0.

“For me, there is nothing more exciting than seeing innovation and accountability in their purest form, and the Team Sonnenwagen is exactly that” emphasizes Dr. Thorsten Dreier, Chief Technology Officer at Covestro. “Since 2018, they have inspired us because in them we recognize the same spirit we see in our partners, customers and in ourselves: people who move forward when others hesitate, who accelerate the transition to a more circular, climate-neutral future, and who create impact. We are proud to have been their main sponsor and partner for all these years, and we are thrilled to continue pushing boundaries together towards a sustainable future.”

Nassim Lagrou, student at RWTH Aachen University and the new team leader of Team Sonnenwagen, shares this enthusiasm: "We are incredibly proud that Covestro continues to be part of our journey. Over the years, they have proven to be so much more than a sponsor: they are a great partner who brings excellent material solutions and expertise to the table. Whenever we faced a challenge, Covestro was there. Not just with materials and expertise. But as people who really care and share our passion for the Sonnenwagen. It’s about winning together and sharing the same mission, passion and values. That means the world to us."

A successful partnership with a strong track record

The partnership between Covestro and Team Sonnenwagen can look back on an impressive track record of success: European Champions in 2022 at the iLumen European Solar Challenge in Zolder, winners of the Italian Solar Challenge in Imola, as well as additional podium finishes at the European Solar Challenge 2024. With their current solar car, “Covestro Æthon”, the team has continued this success, achieving a top result with fourth place at the World Solar Challenge 2025¹ , including a new team record in qualifying.

More than ten different Covestro materials are used in Æthon. Highlights include the more sustainable, mass-balanced Vulkollan^®, which cushions impacts between the battery and the body, as well as Makrolon^® TC, a thermally conductive polycarbonate used for battery temperature regulation.

This is complemented by a resource-efficient coating that cures at room temperature, along with a seat made from chemically recycled automotive seat foam, combining comfort with sustainability. Additional materials are used in components such as the cockpit canopy, outer shell, headlights, seat, and steering wheel.

For the newly formed Team Sonnenwagen, the next highlight is already on the horizon this year: on September 19 and 20, the team will compete in the European Solar Challenge in Zolder, Belgium, aiming once again for a podium finish. Construction of the new Sonnenwagen will begin in the autumn. With this new car, the team will line up at the World Solar Challenge in Australia in 2027, with the clear goal of competing for victory once again.

_{¹ The World Solar Challenge is an international race for solar-powered cars. It runs 3,000 kilometers from Darwin to Adelaide through the Australian outback. It is considered the world’s toughest competition for solar mobility, in which teams from universities around the world compete against one another.} 

Following Covestro’s acquisition of Pontacol, selected thermoplastic adhesive film products will be showcased at the Covestro booth. Fully integrated into the Covestro portfolio, Pontacol^® solutions expand the company’s range of adhesive and functional film offerings for customers across key markets.

Textile Coatings

The Covestro Textile Coatings team will present waterborne, partially bio-based, and mass-balanced polyurethane (PU) technologies for technically demanding coated textile applications. Exhibits include an automotive door panel design for a concept car, developed jointly with Marquardt Group and E Ink, that integrates a responsive color-changing e-paper display behind a see-through PU-coated synthetic surface. Based on waterborne INSQIN^® PU technology from Covestro, the transparent coated film enables vivid display visibility while meeting the performance and haptic requirements of automotive interiors.

The team will also demonstrate how antimicrobial PU-coated textiles, combining INSQIN^® with AGXX technology from Heraeus Precious Metals, can deliver enhanced hygiene and durability in high-contact applications.

Specialty Films

The Covestro Specialty Films team is presenting its high-performance thermoplastic polyurethane (TPU) film portfolio, specifically engineered to meet demanding technical requirements across diverse industries. Dureflex^® and Platilon^® TPU films deliver exceptional flexibility, durability, and consistent performance in applications ranging from automotive interiors to high-stress sports equipment and innovative cured-in-place pipe (CIPP) systems that enable pipe repair without disruptive excavation.

At the exhibition, visitors can experience smart technology concepts where Covestro's TPU films serve as substrates for flexible printed electronics in protective apparel. The advanced Platilon^® TPU films enable integrated electroluminescent features that significantly enhance visibility and safety in low-light conditions. This concept illustrates Covestro’s commitment to innovation and functional, high-performance solutions.

Thermoplastic Polyurethanes (TPU)

The TPU team will present Desmopan^® AIR, a durable, versatile, and easy-to-recycle material for cushioning applications. Desmopan^® AIR technology introduces a new class of customized TPU-based cushioning solutions. As it can be recycled through simple thermo-mechanical processing, it helps manufacturers develop high-quality cushioning products with improved sustainability. TPU-based cushioning structures can also be combined with other TPU applications, such as TPU nonwoven materials, enabling monomaterial designs.

In addition, the team will present Desmopan^® FLY, an ultra-flexible, low-viscosity TPU solution engineered for Supercritical fluid (SCF) foam injection molding. It enables the production of thin, durable, and highly flexible films and textile applications, combining outstanding wear resistance with reduced material weight.

A shared focus on enabling the textile industry

The company’s presence at Techtextil 2026 emphasizes how raw material innovation can help textile manufacturers meet evolving regulatory, environmental, and market demands, while maintaining efficient production and high product performance.

“We look forward to presenting our material solutions at Techtextil and demonstrating how they can translate into practical progress for the textile industry,” said Dr. Torsten Pohl, Head of Global Textile Coatings at Covestro. “Together with our partners and customers, we will continue to explore applications that support more sustainable products and more efficient manufacturing.”

Techtextil will be held at Messe Frankfurt from April 21–24, 2026. Attendees can find Covestro in Hall 11.0, Booth C79.

Additional information on Covestro’s presence at the Techtextil can be found here.

The so-called People Mover, which will be tested on public roads this year at speeds of up to 50 km/h, is the result of a project funded by the Federal Ministry for Economic Affairs and Energy (BMWE) and the European Union.

"The People Mover is more than just a vehicle – it's a showcase for the future of mobility," explains Jochen Hardt, Head of Global Marketing Mobility at Covestro. “It also vividly demonstrates the 'Material Effect,' for example in the 381cm large windshield made of polycarbonate. Additionally, we considered recycling during the design process and worked with three fully recyclable monomaterials Arfinio^®, TPU and Polycarbonate that can be found either in interior or exterior.”

Material Effects for the Major Trends in Mobility

The materials used in the People Mover demonstrate Covestro's Material Effects and include, for example, Makrolon^® AG for the 381cm panoramic glazing. Covestro can offer this innovative polycarbonate solution based on mass-balanced raw materials from post-consumer waste.

For the autonomous driving systems, opaque but sensor-transparent Makrolon^® AX ST is used for multi-sensor system covers. This innovative solution enables seamless and invisible integration of sensor technology while providing resistance to vandalism and stone impacts.

In the interior, the lightweight, high-quality, and fully recyclable monomaterial Arfinio^® is used in a vehicle for the first time. The material combines a stone-like appearance and feel with high resistance to mechanical stress, UV radiation, and wear.

A consistent monomaterial approach with recycling in mind was also pursued for the seat upholstery. Printed TPU-based solutions made of Desmopan^® AIR provide high seating comfort combined with high abrasion resistance and easy cleaning – a crucial factor for vehicles in continuous public transit operation.

Monomaterials Facilitate Recycling

The use of monomaterials also facilitates recycling at the end of the lifecycle and supports SUE's claim to consider sustainability not only in the propulsion system but throughout the entire vehicle architecture.

"With SUE, we pursued a user- and design-centered approach from the beginning," says Alexander Uedelhoven, founder and project manager of SUE and authorized signatory at UE | STUDIOS. "We wanted to develop not just a technologically advanced vehicle, but one optimally aligned with passenger needs in terms of service, information, ergonomics, and aesthetics. The materials and extensive technical expertise from Covestro gave us the freedom to implement this vision without compromises."

The project was realized in collaboration with renowned partners, including the Institute for Automotive Engineering of the Lower Saxony Research Centre for Automotive Technology (NFF), TÜV Nord, the Fraunhofer Institute EMFT, and Deutsche Bahn (DB Regio).

As initiator, project manager and vehicle manufacturer, UE | STUDIOS are responsible for the overall concept, complete development, design and production of the SUE People Mover.

The capacity expansion at Covestro Integrated Site Shanghai (CISS) comes in response to growing customer demand for TDI, a key component used primarily in flexible foams for furniture, mattresses and automotive applications. The debottlenecking project was completed on schedule and will enable Covestro to provide more reliable supply to customers throughout the region.

Commitment to supporting customer growth

"This investment demonstrates our commitment to supporting our customers' growth in Asia Pacific, particularly in China and the broader region," said Xiaobin Zhong, Covestro's Head of Performance Materials Sales in the Asia Pacific region. "By expanding our TDI capacity in Shanghai, we ensure reliable supply to meet increasing market demand while reinforcing our position as a preferred partner for the furniture and automotive industries."

The site, located in the Shanghai Chemical Industry Park, is one of Covestro's largest production facilities worldwide. The successful debottlenecking project involved optimizing existing production processes and infrastructure rather than building new production lines, resulting in a more resource-efficient approach to capacity expansion.

Disciplined investments in growth areas

"This achievement reflects our strategy of growing through smart, efficient investments that deliver maximum value to our customers," said Hermann-Josef Doerholt, Head of Performance Materials at Covestro. “It also further strengthens Covestro's global TDI production network, which includes world-scale plants in Dormagen, Germany and Baytown, Texas, ensuring that we can reliably serve customers across all major regions.”

TDI is an essential component for producing flexible polyurethane foams, which provide comfort in furniture, mattresses, and car seat

This is important because the conventional vehicle part coating process typically involves multiple steps, each of which adds cost, uses energy, and limits design freedom. Direct Coating from Covestro transfers the molded part to a second cavity and applies a low viscosity 2K PU that cures in the mold. This integrated process requires no conventional coating- or painting lines, accelerates cycle times, streamlines operations, and enables more flexible, scalable production of a range of coating designs, including those featuring haptics and visual effects.

“With a broad network of partners across the entire value chain, we are well-positioned to support the global rollout of Direct Coating,” said Benjamin Herzberg, Technology Expert IMC at Covestro. “We have over two decades of proven experience in the Direct Coating process, with a strong focus on joint projects across the automotive industry. Our application and scale-up expertise is anchored across technical centers worldwide and backed by a strong IP portfolio. Our latest customer support enhancement is a tool that compares cost and CO₂ emissions with the conventional manufacturing process.”

End-to-end solutions and support

Covestro also offers tailored polycarbonate substrates such as Makrolon^® IMC2477. This solution delivers excellent adhesion to polyurethane coatings while maintaining good optical properties in both transparent and colored opaque finishes. Additionally, Covestro has designed dedicated polyurethane coating raw materials for Direct Coating applications. These materials include fast-curing, low-viscosity polyisocyanates and polyols suitable for these applications.

“Customers can accelerate their time-to-market by benefiting from guidance on mold design and process optimization, as well as using our facilities to trial designs and validate parts and production conditions,” added Thomas Baeker, Marketing Manager for Industrial and Automotive Coatings at Covestro.

Since 2021, a leading German automotive manufacturer has used Covestro products for Direct Coating components in both exterior and interior vehicle applications.

More information
Tier suppliers and OEMs interested in evaluating Direct Coating can find out more by visiting the Covestro website.

Additionally, our technical experts can also provide suppliers and OEMs with a bespoke cost calculation tool and access to Covestro technical labs.

Latest info on Covestro’s K fair presence:

• Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

Additional Press Releases:

• From Materials to Solutions: Covestro Brings "The Material Effect" to K 2025
• Digital Material Twins in Automotive Design: Imagio^® of Covestro Now Integrated into Autodesk VRED
• Covestro deepens collaboration with Ausell to advance end-of-life automotive plastics recycling
• More speed from design to series production
• From old tires to new car parts: Covestro, Neste and Borealis aim at closing loop for automotive industry 
• Covestro and Deloitte jointly develop Monetization Framework for Circular Economy
• Life Cycle Assessments digitalized: boosting transparency

Covestro at a Glance:

Are you looking for more information? Here you could find further facts about Covestro.

Monique Buch, Chief Commercial Officer at Covestro: "The chemical industry and many of its key customer industries face profound transformations – on the path to circular economy, through AI and digitalization, or due to geopolitics and the realignment of global markets. With our expertise in high-performance materials, process and application development, we remain part of the solution and support our customers in achieving their goals."

The solutions presented at "K" are organized across the booth in the areas of Automotive, Electronics, Healthcare, Sports and Leisure, as well as Sustainable Future. They showcase "The Material Effect" in application across various industries and underline the company's long-term vision of a complete alignment with the circular economy. This vision remains the North Star for Covestro and the industry – despite short-term challenges and overlapping crises that require resilience and adaptability.

Materials with Impact: "The Material Effect" in Practice

Jochen Hardt, Booth Manager and Vice President Global Marketing Mobility in the Engineering Plastics business entity at Covestro: "At our booth, visitors can experience first-hand how 'The Material Effect' becomes reality in concrete applications. We deliberately present not only materials and products but showcase well-designed system solutions that offer real added value to our customers. My team and I at Covestro look forward to engaging with visitors throughout the fair!"

Sustainable Future

In the "Sustainable Future" area, Covestro demonstrates its comprehensive commitment to the circular economy. This includes the "CQ" portfolio, which marks products containing at least 25% alternative raw materials. Another example is the technology developed by Covestro and partners for producing plant-based aniline. Also featured are several car-to-car recycling projects that advance circularity in the automotive industry. For example, the NALYSES project, where Covestro works together with partners like HELLA and BMW on the circularity of headlights. Or a pilot program with NIO, VW, and GIZ for recycling polycarbonate parts. For the latter, visitors will find materials labeled "RE", "RP", and "R" at the booth – these are partly made from alternative raw materials.

Automotive

Highlight in the automotive area: The SUE "People Mover" – a prototype vehicle for public transportation. The autonomous e-shuttle was designed and developed by UE | STUDIOS. It features large-scale, curved 3D polycarbonate glazing as well as seamless integration of driver assistance systems and sensors, also using polycarbonate. The lightweight, highly durable monomaterial Arfinio® is used in the interior, along with a recyclable TPU monomaterial seat. The IMAGIO® tool for digital, photorealistic material twins will also be on display. It is now implemented in Autodesk VRED and makes design processes faster and more efficient.

Electronics

In the electronics area, Covestro showcases innovative NIA-PFAS (not intentionally added PFAS) polycarbonates with flame retardancy for laptop covers and IoT device housings. Additionally, a recyclable antenna housing made of Makrolon® monomaterial will be on display, combining optimal signal transmission with weight reduction.

Healthcare

In the healthcare booth area, Covestro presents material solutions that combine sustainability with performance and reliability: From medication delivery with particularly thin-walled, more easily recyclable monomaterial injectors to resistant housings for diagnostic devices that withstand disinfectants. Such devices can furthermore be made with NIA-PFAS material types for flame retardancy, and support the seamless integration of functionality such as touch operation and signaling in an attractive design.

Sports and Leisure

In the sports and leisure area, visitors will find applications such as the e-surfboard by Awake. Covestro materials can be found, for example, in the easily and quickly replaceable battery, with thermally conductive and flame-retardant polycarbonate for improved battery performance. Durable TPU-based materials on the grip of the replaceable battery additionally provide pleasant haptics and comfort.

Press Tour for Media Representatives

Media representatives are cordially invited to experience Covestro's exhibition booth at K 2025 in person. A press tour will take place on the first day of the fair, October 8, 2025, at 3:00 p.m. at booth A75 in Hall 6.

The tour offers a comprehensive overview of all focus areas as well as the opportunity for discussions with technical experts about "The Material Effect" and the implementation of the circular economy strategy in concrete applications. There will also be opportunities for individual interviews.

For more information about Covestro at K 2025, please visit Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

At the same time, according to the review process of the European Chemicals Agency (ECHA), conventional antimicrobial silver technologies face the challenge of meeting the requirements of the BPR due to concerns over potential harm to human, animal, and ecological health. Many are now set to be phased out in the years ahead.

To address the demand for more sustainable antimicrobial surface coatings, Heraeus Precious Metals created AGXX: a system that eliminates a wide range of bacteria, fungi, and viruses without releasing harmful silver-ion components. AGXX works due to a catalytic reaction of two precious metals that converts oxygen into reactive oxygen species (ROS) using moisture derived from air humidity. These ROS eliminate microbes by disrupting their outer cell membranes, organelles, and DNA.

Martin Danz, Global Head of Antimicrobial Technologies at Heraeus Precious Metals said: “AGXX is skin-friendly,* BPR-compliant, and suitable for a wide range of applications. Results from our joint tests with Covestro now show that AGXX can be combined with Impranil^® PU dispersions to add long-lasting antimicrobial properties to textile coatings for synthetic materials.”

Tests also revealed that incorporating AGXX with INSQIN^® textile coatings technology from Covestro does not impact manufacturing processes. “We found that AGXX could be mixed with our Impranil^® products without dulling the performance or properties of either solution or requiring any changes to manufacturing processes for coated textiles,” said Dr. Torsten Pohl, Global Head of Textile Coatings at Covestro. “When combined with AGXX, our INSQIN^® technology maintains its cleanability, flexibility, and ability to withstand usage over long periods. For textile coating manufacturers, this tried-and-tested guide formulation offers a fast and effective way to infuse their coatings with safer and more sustainable antimicrobial properties and still gain the sustainability improvements of our low-VOC waterborne PU dispersions.”

With demand for hygienic, reliable, BPR-regulation-compliant, and safer textile coatings expected to increase, the combination of AGXX and INSQIN^® technology will enable textile manufacturers to quickly adapt to the rapidly evolving needs of the sharing economy.

To see how the combined guide formulation works in real-world applications, visit Techtextil 2026 in Frankfurt from April 21 to 24, 2026. Items coated with AGXX and Impranil^® will be on display at the Covestro booth.

*Tested by bio compatibility test according to ISO 10993-5

About Heraeus Precious Metals
Heraeus Precious Metals is globally leading in the precious metals industry. The company is part of the Heraeus Group and covers the value chain from trading to precious metals products to refining and recycling. It has extensive expertise in all platinum group metals as well as gold and silver.

With more than 3,000 employees at 16 sites worldwide, Heraeus Precious Metals offers a broad portfolio of products that are essential for many industries such as the automotive, chemicals, semiconductor, pharmaceutical, hydrogen and jewelry industry. Find more information on the Heraeus Precious Metals website. www.heraeus-precious-metals.com

The integration of the Imagio^® material database into Autodesk's VRED, one of the world's leading design platforms for cars and other transportation vehicles such as aircraft or rail vehicles, provides designers worldwide with immediate access to photorealistic representations of color, gloss, transparency, translucency, or surface texture of the versatile polycarbonate materials of Covestro.

"The integration of our digital sample library into Autodesk VRED is a milestone for both partners," says Dr. Tobias Rausch, Business Development Manager for Digital Sampling in the Engineering Plastics Business Entity at Covestro. "We are effectively lowering the entry barrier to our material world for designers of vehicles and auto parts. They can now easily find our polycarbonate materials and their many facets and try them out realistically for their application with just a few clicks. This saves a series of iterations and thus time, money, and emissions associated with transport and sample production."

Higher Efficiency and Precision in Design

The time saved is a crucial advantage in an industry like automotive, where development cycles are becoming shorter and efficiency in the design process is increasingly important. The ability to easily experiment with photorealistic effects and surface structures that can be applied to the respective application via drag-and-drop is a major advantage. Unlike physical samples, this approach also leaves less room for interpretation and thus errors, which has always existed when transferring properties from a sample to the final application.

"The integration of Imagio^® significantly expands the potential of our design portfolio and helps our users enormously," explains Marek Trawny, Director of Product Management - Automotive & Conceptual Design at Autodesk VRED. "In a time when speed and precision in the design process are crucial, photorealistic digital material twins offer our users a decisive advantage. Designers can now immediately and accurately see how polycarbonate materials will look in their designs. This aids decision-making and fuels creativity."

Up next: Mechanical Properties or Weathering Simulations

Autodesk is one of the main providers of design software for the automotive industry and is used by leading manufacturers. The exclusive presence of Covestro in this digital design tool, where design and material decisions are made, is a strategic milestone for both companies. Future functionalities are planned, such as connections to simulation tools for mechanical properties, rheology, or weathering simulations. This will allow designers to simulate how materials behave after years of exposure to sun and rain and visualize the resulting changes in appearance.

The Imagio^® integration is available with Autodesk VRED Professional 2026.1. Users need an Imagio^® account, which is available for business customers and public organizations. For users of other visualization platforms, Imagio^® remains accessible through its web interface, offering the same comprehensive material library with downloadable AxF files compatible with most leading rendering software programs.

Covestro at K 2025

This project also underlines "The Material Effect" – the guiding concept of the presence of Covestro at this year's K trade fair in Düsseldorf. At stand A75 in hall 6, Covestro will place special emphasis on progress and innovations in the areas of sustainable future, automotive, electronics, healthcare, sports and leisure.

https://www.autodesk.com/products/vred/overview
Imagio Color Finder
https://solutions.covestro.com/en/highlights/articles/cases/2025/digital-material-twins-for-automotive-design

In qualifying, the Covestro Æthon secured pole position with a time of 1:52.50 minutes, setting a new team record. Never before has a Team Sonnenwagen solar race car been faster on the circuit in Darwin. After five days of racing, the new Sonnenwagen Covestro Æthon finished in fourth place – a world-class performance in a strong field of 37 teams from 18 countries, made possible in part by Covestro products.

“Regardless of the outcome of the race, Team Sonnenwagen has done a great job in my opinion,” says Dr. Thorsten Dreier, Chief Technology Officer at Covestro. “What these students from Aachen have achieved with the design of their solar car is a demonstration of innovative strength, team spirit, and determination. They deserve nothing but congratulations. And I am always delighted that we are able to support this extraordinary team with our innovative and sustainable technologies and our expertise.”

“We are incredibly proud of what we have achieved,” says Leonie Brandt, Chair of Team Sonnenwagen Aachen. “Just finishing this race is an enormous achievement – and with Æthon, we made it into the ranks of the world’s best teams. Our vehicle proved itself under extreme conditions, and we are taking away many important insights.”

Covestro has been supporting Team Sonnenwagen since its founding in 2017 and has been its main sponsor and technology partner since 2018. The company is convinced that more sustainable high-performance plastics are key to climate-neutral and circular mobility. Together with customers and partners, Covestro is continuously developing new material solutions and recycling technologies for this purpose.

As with previous vehicles, the Æthon also relied on more sustainable high-performance plastics from Covestro – this time even more than ever before: over ten different materials from the company were used in the car.

One example of the application of our raw materials is chemically recycled car seat foam, which offers comfort while conserving resources. Sustainable mass-balanced Vulkollan^®, a particularly resilient elastomer that absorbs shocks between the battery and the chassis, was also used to protect the structure. For the cell holders, the team used Makrolon^® TC, a thermally conductive polycarbonate that helps to reduce the temperature during battery charging and discharging, thereby increasing the battery's service life. The coating cures at room temperature and contains a binder with a high proportion of sustainable Covestro raw materials. In addition, other Covestro raw materials were used as materials in the cockpit hood, outer shell, headlights, seat, and steering wheel, for example.

As the world’s largest EV market, China is taking a decisive step with the introduction of the groundbreaking national standard GB 38031-2025: Electric Vehicles Traction Battery Safety Requirements. Effective from July 2026, this regulation demands that batteries must not catch fire or explode—even in the event of a thermal runaway. These stringent requirements are expected to shape global safety standards in the years ahead.

Breakthrough flame-retardant encapsulation foam technology

Covestro’s newly launched Baysafe® BEF flame-retardant encapsulation foam series is designed to minimize thermal propagation between battery cells—tackling a key safety concern that has challenged consumer trust in EVs. The lightweight foam delivers superior flame-retardant performance by effectively inhibiting fire spread, significantly enhancing battery safety in applications ranging from EVs to portable energy storage systems.

“This innovation represents a significant step toward enabling sustainable mobility through enhanced safety,” said Akhil Singhania, Global Head of PU Specialties in Covestro’s Tailored Urethanes Business Entity. “By launching our advanced flame-retardant technology, Covestro reaffirms its commitment to innovation and strengthens our product portfolio to meet the evolving needs of the EV industry.”

This development comes at a pivotal time as EV adoption accelerates globally and safety regulations become more demanding. As Chinese automotive companies expand internationally, Covestro’s innovative materials solutions illustrate how technological advancements support successful cross-border market growth.

Comprehensive solutions for the new energy ecosystem

Beyond encapsulation foams, Covestro offers a wide range of polyurethane-based solutions for EV batteries, including battery covers and shock-absorbing materials. The new Baysafe® BEF technology further strengthens Covestro’s position in the fast-growing new energy sector, supporting safer, more reliable electric mobility applications such as new energy vehicles and e-bikes, as well as portable battery generators.

With continued innovation in materials science, Covestro is supporting the development of next-generation electric transportation by providing a reliable technological foundation that meets evolving safety and performance requirements.

The more than 20 innovation stories that Covestro presents at its booth are closely linked to this guiding idea and the company's long-term vision of becoming fully circular. This vision is gaining additional importance under the current circumstances – short-term challenges and overlapping crises that require resilience and adaptability.

Covestro’s CEO Markus Steilemann emphasized this at the traditional K pre-press conference: "The world seems to have gone off track, and the chemical industry is feeling the full force of the current multiple crises. At the same time, the future will be ever greener and smarter. At Covestro, we are paving the way for that for many sectors with our recyclable, climate-neutral high-performance plastics – whether in e-mobility and autonomous driving, efficient buildings, or digitalization. We are excited to showcase the diverse and beneficial effects of our materials for our customers and partners at this year's K trade fair."

Covestro's Guiding Idea: "The Material Effect"

At booth A75 in Hall 6, Covestro will place special emphasis on progress and innovations in the areas of Sustainable Future, Automotive, Electronics, Healthcare, and Sports & Leisure. Among the highlights at the booth will be a new concept vehicle for public transportation: The SUE "People Mover". The self-driving urban e-shuttle has been developed by UE | STUDIOS. It features full polycarbonate glazing, polycarbonate for lidar sensors, as well as the lightweight and highly durable mono-material Arfinio^® and TPU. Also among the exhibits is the digital sampling tool IMAGIO^®, which enables realistic digital visualization of product designs, thereby replacing physical samples with digital material twins in early development phases.

With these and many other stories and exhibits at the booth, Covestro demonstrates under this year's guiding idea "The Material Effect" what role high-performance materials play in a sustainable world. "The Material Effect" combines best in class materials with process and innovation expertise, enabling the leap from laboratory to industry. "It is precisely this unique combination of material science, process- and application development that makes the decisive difference," said Jochen Hardt, K 2025 project lead and Vice President Global Marketing Mobility in the Engineering Plastics business entity at Covestro, at the press conference. “'The Material Effect' enables our customers and partners to achieve more – in terms of sustainability, circularity, and performance of their products.”

Progress Towards Corporate Vision and Strategy

Covestro pursues a clear strategic vision: to become fully circular and make the circular economy a global guiding principle. This includes the use of alternative raw materials, switching to green energy, and developing advanced recycling technologies. The company has set a goal to become climate-neutral in its own operations (Scope 1 and 2) by 2035 and to achieve complete climate neutrality along the entire value chain (Scope 1-3) by 2050. To this end, Covestro has already signed eleven power purchase agreements (PPAs) and now covers around 16 percent of its global electricity needs from renewable sources.

Furthermore, Covestro is consistently expanding the use of alternative raw materials – with the goal of largely avoiding the use of fossil primary raw materials in the long term. The company is to that end currently developing and testing novel recycling technologies for polyurethanes, polycarbonates, and elastomers.

The commitment to the circular economy is furthermore reflected in the product portfolio: Products with the brand suffix "CQ" – which stands for Circular Intelligence – contain at least 25 percent alternative raw materials. For polycarbonates, Covestro differentiates its offering with specific labels: "RE" stands for products based on renewable raw materials and produced with renewable electricity.^* "RP" identifies products with chemically recycled post-consumer waste.^* "R" designates products with mechanically recycled material content.

Such products aFor more information about the trade fair presence, visit:

For more information about the trade fair presence, visit:
Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

_{* attributed via mass balancing}

Latest info on Covestro’s K fair presence:

• Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

Additional Press Releases:

• Covestro deepens collaboration with Ausell to advance end-of
• More speed from design to series production
• From old tires to new car parts: Covestro, Neste and Boreali
• Covestro and Deloitte jointly develop Monetization Framework
• Life Cycle Assessments digitalized: boosting transparency

Covestro at a Glance:

Are you looking for more information? Here you could find further facts about Covestro.

"What the students from Team Sonnenwagen have achieved here, alongside their regular studies and exams, is really impressive," said Dr. Thorsten Dreier, Chief Technology Officer at Covestro, during the unveiling. "The collaboration between our experts and the students has been and continues to be a great inspiration. Together with all the other strong partners, we're demonstrating what tomorrow's mobility can look like. We’re proud that we can contribute innovative materials and know-how to help shape a more sustainable future."

"Æthon" is the result of twelve months of intensive development. Over 40 students from RWTH and FH Aachen designed, tested, and built the vehicle alongside their studies – supported by Covestro as main sponsor and technology partner. The Leverkusen-based materials manufacturer contributes more expertise than ever: More than ten different Covestro materials have been incorporated into the vehicle – a record in the project's history. The solar car thus provides the company with the additional opportunity to test materials for series vehicle production under extreme conditions.

"We are very proud of Æthon. The entire team has put their heart and soul into this project," explains Leonie Brandt, Chair of Team Sonnenwagen. “The same goes for our partners, especially Covestro, who have been involved in the project for so long. Without this expertise and support, there would be no Sonnenwagen, and we wouldn't have been as successful as we've been. This year, we want to repay everyone involved with a victory in Australia. We're looking forward to it!”

Material Solutions for Future Mobility

Like its predecessors, the new Sonnenwagen relies on sustainable and innovative materials. The highlights: chemically recycled foam in the driver's seat – proving that comfort and circular economy can go hand in hand. Chemically recycled Vulkollan®, an extremely durable elastomer, is also used. It dampens impacts between battery and body, contributing to the structure's longevity. Covestro materials are also used in the battery cell holders, aerodynamic outer shell, interior trim, headlights and turn signals, as well as in the coating.

New Rules, New Challenges – New Opportunities

Such high-tech materials are more important than ever this year, as new rules apply at the World Solar Challenge: The allowed battery capacity has been halved, and the development time shortened by two months. At the same time, cars are allowed to be longer – an opportunity Team Sonnenwagen consistently utilizes with "Æthon": At 5.80 meters, it's longer and features six square meters of solar cells – a full two square meters more than its predecessor "Covestro Adelie." Additionally, the racing calendar brings a new challenge: This year, the race takes place at the end of the Australian winter - and thus earlier than usual. For the team, this meant less time for development and testing.

The official unveiling of Æthon marks the beginning of the intensive testing phase. In July, Team Sonnenwagen will depart from Aachen to Australia to compete against over 50 teams from 24 countries – including numerous leading international universities. Covestro continues to support the project on its journey – with the shared goal of advancing sustainable mobility and bringing the world championship title to Aachen with the power of the sun.

"This new line of polycarbonate represents a significant step in supporting the automotive industry's transformation towards a circular future," said Lily Wang, Global Head of the Engineering Plastics Business Entity at Covestro. "By offering high-quality PCR materials derived from end-of-life headlamps, we're enabling our customers to meet increasingly stringent regulatory requirements while contributing to closed-loop recycling of automotive plastics."

Under this initiative, Covestro has been collaborating with partners, including Chinese recycler Ausell and leading automakers, to establish closed-loop pathways for high-value plastics from end-of-life vehicles (ELVs). This program focuses on strengthening recycling processes and establishing reliable supply chains for high-quality recycled materials from automotive waste streams. Through this partnership, Covestro and its value chain allies have developed practical solutions for collecting and mechanically processing end-of-life headlamps into high-quality PCR grades suitable for a range of automotive applications.

"This partnership underscores the importance of cross-sector collaboration in driving the circular economy forward," said Martin Hansen, Regional Director of GIZ in East Asia. "By bringing together key industry players, we are not only creating viable solutions for recycling high-value plastics from end-of-life vehicles but also fostering innovation that supports a sustainable, closed-loop material flow in the automotive industry."

The introduction of these new PCR grades comes at a critical time as the automotive industry, one of the most resource-intensive sectors, faces increasing environmental challenges and regulatory pressures. The EU's End-of-Life Vehicle Directive, which sets recycling targets, along with China's Extended Producer Responsibility (EPR) program and growing sustainability requirements in key global markets, are pushing automotive manufacturers worldwide to seek innovative and sustainable material solutions that comply with evolving regulations.

Covestro’s new PCR grades meet the high-performance standards required for demanding automotive applications, offering excellent surface quality for superior aesthetics and adhering to strict Vehicle Interior Air Quality (VIAQ) requirements. This combination of sustainable content and premium performance empowers automotive manufacturers to meet both regulatory demands and environmental goals without compromising on product quality.

As part of its broader commitment to sustainability and the circular economy, Covestro continues to expand its portfolio of recycled-content materials. In recent years, the company has introduced PCR polycarbonates with up to 90 percent recycled content, and opened its first dedicated mechanical recycling compounding line for polycarbonates in Shanghai. Last year, it introduced a new range of polycarbonates based on chemically recycled, attributed material from post-consumer waste via mass balance for the first time.

"The new production facilities are equipped with state-of-the technology to enable an efficient production and thereby reduce our CO₂ emissions," says Thorsten Dreier, Chief Technology Officer of Covestro. “With the expanded capacity, we can meet our customers' growing demand for innovative specialty films, especially in medical technology, in the region Asia-Pacific and strengthen our Solutions & Specialties segment."

Covestro has been operating a production facility for Specialty Films in Thailand since 2007. The range comprises polycarbonate films from the Makrofol^® range and Bayfol^® products made from polycarbonate blends. These high-performance specialty films are used in many applications across multiple industries, such as healthcare, mobility and Identification Documents.

“The new production facilities are important to us because it enables faster time to market and at the same time expands our market access in Asia-Pacific.” says Aukje Doornbos, Global Head of the Specialty Films business entity. “With market-focused innovations and a stronger customer orientation we want to drive growth for Covestro.”

Since 2022, the Map Ta Phut site is ISCC PLUS certified, enabling it to manufacture and supply mass-balanced products. With the mass balance approach, bio-based or recycled raw materials are fed in at an early stage of raw material extraction and mathematically allocated to the finished products. This saves fossil raw materials and reduces CO₂ emissions, while the quality of the mass-balanced products remains identical to that of purely fossil-based products. With this drop-in solution, manufacturers can continue to use their proven formulations, equipment, and processes.

ISCC is an internationally recognized sustainability certification for biomass and bioenergy. The standard covers all stages of the value chain and is used worldwide. Customers can use these products in their established processes and apply them to meet their sustainability goals. In addition, Covestro already offers a range of films made partly with plant-based raw materials or partly from recycled plastics.

"This investment in our U.S. compounding plant is an important component of our 'Sustainable Growth' strategy. With this expansion, we can meet our customers' growing demand for specialized polycarbonate materials, grow together with our customers, and strengthen our position as a leading provider of polycarbonate materials in North America," says CTO Thorsten Dreier. "The move also aligns with our strategy to produce in the region for the region, to manufacture close to our customers and ensure reliable supply."

The capacity expansion is an important step to meet the growing demand for high-quality materials for the automotive, electronics, and healthcare industries in North America. "To be successful in these markets, you need the right portfolio, consistent quality, and supply reliability, as well as solution-oriented technical expertise,” says Lily Wang, head of the Engineering Plastics Business Entity. "The expanded production capacity for differentiated polycarbonates enables us to better serve our customers' complex needs for high-quality, high-tech materials with individualized properties.”

Covestro already has an established R&D center in Pittsburgh and is now doubling down on its U.S.-based compounding capability. In the future, both facilities will work even more closely together to drive the technology transfer from lab to industrial production to support major transformation processes, such as the electrification and automation of mobility, sustainable developments and digitalization.

“This investment, which follows our recent announcement of an almost 40 million Euro investment in our R&D capabilities in Pittsburgh, underscores how critical our U.S. sites and the U.S. market are to Covestro’s global strategy,” says Samir Hifri, chairman and president of Covestro LLC. “The expanded capacity of our polycarbonate compounding capabilities in Ohio will both help us better supply our customers as well as represent a commitment to our employees at the site, the Hebron, Ohio community, and the U.S. market as a whole.”

Construction of the new production lines is scheduled to begin in 2025, with operations starting by the end of 2026.

Covestro is one of eight companies, including partners from the fields of AI, information technology for low-altitude aviation and carbon fiber composite materials, to sign a Memorandum of Understanding (MOU) with GOVY, a newly established subsidiary of GAC dedicated to the development of eVTOL aircraft. As a key partner in this ambitious project, Covestro brings its unique expertise in high-performance materials and sustainable solutions for the advancement of next-generation flying cars.

“Our collaboration with GAC represents a significant step forward in transforming urban air mobility. By leveraging Covestro’s expertise in sustainable and innovative materials, and GAC’s visionary leadership in flying car development, we are poised to create solutions that redefine the possibilities of urban transport,” said Lily Wang, President of the Engineering Plastics Business Entity at Covestro.

“We are committed to pushing the boundaries of innovation and bringing the future of mobility closer to reality,” said Su Qingpeng, General Manager of GOVY. “Partnering with Covestro and other industry leaders allows us to accelerate the development of our flying cars, creating safe, more sustainable, and groundbreaking transportation solutions for urban environments.”

China is making significant strides in the development of eVTOL aircraft, leveraging its advancements in battery technology to integrate these innovations into urban transportation systems. This strategic focus is driven by the potential of eVTOL vehicles to alleviate urban congestion, reduce pollution, and enhance connectivity, aligning with consumer desires for efficient transportation and the government’s goals for technological innovation and sustainable urban development. These vehicles are designed for short-distance urban travel, with current models offering ranges suitable for inter-city commutes.

Under the agreement, Covestro and GOVY will collaborate on several priority areas. Key initiatives will include developing innovative polycarbonate glazing solutions to reduce vehicle weight while maintaining high performance and safety standards, and exploring materials for smart and efficient lighting systems tailored to the unique requirements of eVTOL aircraft. The collaboration will also address high-performance materials that enable seamless integration of smart systems and components. A strong emphasis will be placed on low-carbon solutions, utilizing materials with attributed bio-circular content and recycled feedstocks to reduce emissions across the vehicles’ lifecycle.

At the signing ceremony, a demo flying car was unveiled, featuring an impressive range of 200 kilometers in just 40 minutes. This prototype showcases a hybrid design that integrates both fixed-wing and rotary-wing capabilities, combining the efficiency of conventional airplane-like forward flight with the vertical takeoff and landing versatility of helicopters. Pre-order of such models will begin in 2025, heralding a new era in personal and urban transportation.

These new displays overcome the performance, size and geometric limitations of traditional HUD systems, enabling the practical and scalable implementation of multiple displays in one windshield and elsewhere in side-light glazing. Proof of concepts (PoCs) developed with OEMs will be showcased at CES 2025 in Las Vegas from January 7–10.

The MOU builds on years of collaboration, leveraging each company’s technologies to manufacture holographic-enabled transparent HUDs for the automotive market. It enables to look into the steps needed to setup and establish the required facilities and manufacturing capacity, ensuring an efficient, market-ready supply chain to meet the planned production timelines of OEMs wishing to adopt the technology for new driver and passenger experiences. The partnership aims to accelerate the commercialization of the HUD solution, with Eastman leveraging its relationships with automotive OEMs and Tier One suppliers.

A proven solution

In 2024, Ceres and Eastman demonstrated the latest holographic transparent display HUDs to OEMs in Europe, the USA, and China. These HUDs featured multiple transparent displays within a single, fully laminated windshield, each measuring up to 400mm by 300mm. Custom-designed holographic optical elements (HOEs) were incorporated into a single sheet of Bayfol HX^® film, laminated with Eastman’s new developed interlayer stack, achieving the industry's largest field of view.

This achievement was enabled by combining Covestro’s expertise in photopolymer films, Ceres’ digital mastering and HoloFlekt^® roll-to-roll replication system, which produces finished films up to 1400mm wide, and Eastman’s solutions to encapsulate functional films into automotive approved laminates.

“This agreement solidifies our collaboration and moves us closer to delivering a full-stack solution for innovative display implementations,” said Hemant Dandekar, Eastman's global commercial director of automotive for advanced materials, interlayers. “With the building blocks and relationships in place, we’re excited to define a path to viable holographic transparent displays globally.”

“Our Bayfol^® HX enables next-generation truly transparent projection displays for windshields while meeting the high automotive safety requirements.” said Günther Walze, Head of Holographic Lightguiding at Covestro. “With the necessary establishment of hologram mastering and scalable mass-production replication equipment by Ceres, combined with Eastman’s windshield lamination technology, this innovation is ready for deployment to end customers.”

“We have been working closely with global OEMs for years and are now at a tipping point for adoption and scaling of this display technology,” said Andy Travers, CEO of Ceres Holographics. “This is being driven by a combination of a desire for more safety-oriented and intuitive information display features, pressure from safety regulators to reduce driver distractions, and the accelerated pace of innovation and associated need for differentiation among a new generation of car makers.”

This agreement joins the material expertise of Covestro, Eastman’s interlayer solutions and encapsulation know-how, as well as Ceres capabilities in mastering and high-volume manufacturing technology for the successful commercialization and industrialization of holography in transparent displays for windshields.

A fully functional transparent display windshield demonstrator laminate will be showcased at CES 2025 in both the Eastman/Ceres Holographics demonstration suite at The Venetian Hotel - Murano suite, #3201A, and Covestro’s booth in the North Hall, location #8311.

Since 2020, Covestro has been partnering with Ausell to recycle 1 million 19-liter polycarbonate water barrels annually, converting them into high-performance post-consumer recycled (PCR) polycarbonates for various industries such as electronics, home appliances and automotive. With this strengthened collaboration, Ausell will supply recycled polycarbonates derived from discarded automotive headlamps, which Covestro will then process into high-quality PCR materials for automotive engineering applications. This partnership marks a further step to effectively closing the plastics recycling loop within the automotive sector, reducing waste and carbon emissions while enhancing resource efficiency.

Lily Wang, Global Head of the Engineering Plastics Business Entity at Covestro, said: “We are excited to deepen our partnership with Ausell as we work closely with our value chain partners to accelerate the circular transformation of the automotive industry. Together, we are committed to pioneering sustainable solutions that will lead the way toward a circular and climate-neutral future.”

Xia Wenjun, CEO of Ausell, added: “Our enhanced collaboration with Covestro represents a significant step toward achieving our shared vision of a circular economy. By turning end-of-life automotive components into valuable resources, we are not only reducing waste but also contributing to the development of sustainable materials for future vehicle production.”

The automotive industry, facing increasing regulatory pressures for sustainability, as well as following their own roadmap to “close the loop” of materials, is looking for robust and adapted solutions to their challenges.

This collaboration positions Covestro and Ausell at the forefront of efforts to develop compliant, high-performance materials while addressing the challenges of plastic waste management and resource utilization in the automotive industry. The recycled polycarbonates will not only enhance the sustainability of automotive components but also demonstrate the potential for high-value recycling solutions.

“Our products touch everyday life in thousands of applications, from cars to electronics to footwear. To accelerate circularity and sustainability we need to work closely with our customers and partners along the value chain on adopting alternative raw materials, renewable energy sources and recycling technologies”, says Dr. Guido Naberfeld, Senior Vice President, Head of Sales and Market Development Mobility at Covestro. “We are excited to show some of our latest developments and projects and are eager to engage in discussions about them at this year’s Fakuma.”

The Fakuma in Friedrichshafen, Germany, is a leading annual international trade fair for plastics processing. Visitors of the Covestro booth will discover a set of exhibits ranging from Polycarbonates to Specialty Films to Thermoplastic Polyurethanes, demonstrating how sustainability and performance can go hand in hand across industries.

Key exhibits include an innovative automotive frontend design that combines looks and functionality while also incorporating electronics. The materials used in the concept are Makrolon® and Makrofol®. The same materials can be used to create nearly monomaterial electronic displays, ideal for integration into smart surfaces in kitchens, vehicles and consumer electronics. One demonstrator, featuring in-mold printed elecontric circuits, will be exhibited.

Covestro's recently announced partnership with Neste and Borealis will also have a spot at the booth. It showcases the closed-loop recycling of old tires into highly transparent polycarbonates that can be used in automotive components, such as car headlamps. This innovation exemplifies circularity in the automotive industry through the Makrolon® RP product range, which uses chemically recycled raw materials, attributed via the mass balance approach.

Covestro in general aims to become increasingly circular and climate-neutral, with the goal of operational climate neutrality (Scopes 1 and 2) by 2035, and full climate neutrality by 2050. To make products that are advancing toward these goals easily identifiable, Covestro, besides RE or RP, also uses the “CQ” label. CQ stands for “Circular Intelligence”. CQ ecompasses, for example, products that contain at least 25% alternative, non-fossil raw materials, either as components or through the mass balance methodology. This helps to reduce their carbon footprint while contributing to circularity. Some of the abovementioned and more products can be seen at Fakuma.

Construction is set to begin in late 2024, with the facility expected to become operational in 2025. The center will be outfitted with advanced equipment to address complex market demands and leverage local resources and networks to streamline talent and administrative management.

“Establishing this new application development center in Guangzhou is a strategically important move for us to jointly with our customers leverage on the vibrant Asia-Pacific and especially the Chinese market. The center will also contribute to developing more sustainable TPU solutions, underscoring our dedication to innovation that benefits our esteemed customers and partners,” said Dr. Andrea Maier-Richter, EVP and Global Head of TPU at Covestro. “Together with the ongoing investment in our largest global TPU production site in Zhuhai, we will soon run two powerful engines in two major cities. This highlights our company’s ongoing commitment to growth and its commitment to the innovative capabilities of TPU in particular.”

With the existing regional R&D center in Changhua, the ongoing construction of the largest global TPU production site in Zhuhai and the upcoming APAC application development center in Guangzhou, the collaborative and complementary strengths from the three sites are expected to drive even more powerful regional synergies.

“The new application development center in Guangzhou will play an instrumental role in engaging with major TPU industry clusters across China and APAC, particularly in consumer electronics and specialty extrusion applications,” said Kevin Ho, Head of Sales & Market Development for TPU in APAC at Covestro. “We are not only close to these industry clusters, we are also at the forefront of listening to our customers, partners and the industry value chain. By bolstering our AD capacities, we ever better can sense and meet the nuances and changes and navigate our solutions and services with velocity, agility and customer centricity.“

Covestro is committed to offering sustainable and circular solutions that align with its long-term goals. The Desmopan^® CQ TPU portfolio is a great example, utilizing alternative raw materials such as feedstocks from waste or biomass, attributed via mass balancing. The company as a whole furthermore aims to become fully circular and aims at becoming operationally climate neutrality by 2035, striving to utilize only renewable energy for its operations by then. This lowers the carbon footprint of products like TPU even further. This dedication of the company is also reflected in the investments in its new TPU properties, where such developments shall be driven further.

“We are excited to partner with Li Auto and support their pursuit of intelligence and electrification in automobiles,” said Guido Naberfeld, Senior Vice President, Head of Sales and Market Development Mobility at Covestro, during the MOU signing event at Covestro’s integrated production site in Shanghai. “By leveraging our expertise in engineering plastics and circular solutions, we aim to enable innovative future-oriented mobility solutions and reshape automotive material cycles, driving the industry towards a smarter and more circular economy.”

Under the MOU, Covestro and Li Auto will establish a “Joint Innovation Platform” to drive the development and application of more sustainable engineering plastics with alternative feedstocks, such as bio-waste and recycled sources, across various automotive components. Key initiatives will involve integrating materials attributed with bio-circular content through mass balancing into automotive lighting, functional interior and exterior parts, and smart system components. The two sides also agreed to explore innovative processes and business models for using recycled lighting materials in new automotive parts together with value chain partners.

Under the joint platform, the two sides also seek to deepen their collaboration in developing lighting, smart systems, and thermal management solutions. This will include high-performance optical-grade materials, smart surface technologies and thermally conductive solutions.

“Li Auto is dedicated to implementing the ‘Smart + Electric’ strategy with innovative materials and designs, aiming to offer users a safer, more comfortable, convenient and refined travel experience,” said Liao Mengjun, Vice President of R&D Operations at Li Auto. “Our partnership with Covestro will expedite our exploration in advanced materials, supporting the ongoing enhancement of user product demands.”

During the event, the two parties also unveiled two jointly-developed, industry-leading materials: innovative light-diffusing and infrared-transparent Makrolon® polycarbonates. The light-diffusing polycarbonate allows for a more refined and evenly-distributed illumination effect for smart headlights. Meanwhile, the new infrared-transparent polycarbonate achieves a high transmittance of over 85 percent in the near-infrared spectrum. Compared to conventional black polycarbonate, which absorbs solar energy across the entire spectrum, this new material significantly enhances the light aging resistance of components, contributing to greater durability for the smart headlights of Li Auto.

In line with trends toward lightweight and customized designs in the athletic shoe market, Covestro has launched the Dispercoll^® U high-performance waterborne polyurethane adhesive solution. It is specifically engineered for bonding-challenging special shoe materials and can enhance manufacturing efficiency while supporting energy savings and carbon reduction. With exceptional initial tack performance, the solution can bond lightweight, temperature-sensitive substrates and accommodate innovative shoe designs, resulting in smoother handling and increased productivity. Additionally, its activation temperature can be reduced from 55°C to 35°C, leading to lower energy consumption and reduced carbon emissions during the thermal activation process.

Furthermore, Covestro has developed the Dispercoll^® U PLUS waterborne footwear adhesive solution in response to the footwear industry’s growing interest in one-component solutions that simplify the bonding process. This solution streamlines shoe manufacturing, conserves equipment and labor, reduces material waste, and is also suitable for automated bonding processes. With proven hydrolysis resistance and bonding strength, this solution effectively reduces the risk of debonding in high-performance athletic shoes, thereby extending their lifespan.

Addressing the design trends in the automotive interior segment, Covestro has launched the Dispercoll^® U bonding solution for automotive interior lamination, featuring enhanced heat resistance. By balancing good initial bonding strength with exceptional initial heat resistance, the solution effectively meets the stringent requirements for bonding complex, three-dimensional trim parts under high tensile strength, making the lamination process more efficient. This makes it particularly suitable for applications in 3D-shaped interior trim parts, such as armrests with novel designs and large curved seat back covers. Compared with the majority of marketed solutions, Dispercoll^® U demonstrates superior performance in both green and final heat resistance, better meeting production and application needs by reducing risks such as rebound and bulging.

Covestro has also introduced an upgraded version of Dispercoll^® U PLUS waterborne polyurethane adhesive solution for automotive interiors. It significantly improves heat and climate resistance, addressing the challenges of aging in automotive interiors due to extreme heat and ensuring long-term stability in adhesive bonding performance. It also offers improved storage stability.

Enhancing localization to serve the coatings and adhesives industry

These innovative adhesive solutions were developed at Covestro’s Asia-Pacific Innovation Center in Shanghai. Furthermore, to better serve regional customers, the company now locally produces about 75 percent of its products sold in the coatings and adhesives industry across Asia Pacific.

“Over time, Covestro has expanded our localized R&D and production capacity in Asia Pacific, building an efficient regional innovation and supply network with consistent high quality. This has effectively supported our coatings and adhesives customers in operating and expanding in their respective markets,” said Li Jinqi, Vice President of Coatings and Adhesives Greater China at Covestro. “We’re also pushing forward with our digitalization strategy throughout product development to significantly improve the efficiency of product innovation.”

For example, at the Asia-Pacific Innovation Center, Covestro has developed new digital testing equipment and solutions for assessing initial bonding strength in footwear, replacing traditional subjective manual methods. This digital tool ensures objective, scientific and accurate test results through micromechanical analysis of the adhesion process, helping to shorten the product development cycle and meet customers’ needs for rapid development and launch of high-quality products.

Baypreg® STM employs the Spray-Transfer-Molding process, where PU resins are sprayed onto glass fibers and molded into battery covers, enabling efficient production of composite components. Developed in collaboration with Liyang Shanhu Industrial Co., Ltd., a Tier 1 supplier of automotive parts and battery packs to Chinese and international OEMs, this solution represents a significant advancement that is also cost-effective.

Solution for lighter and high-performance battery covers

This PU solution reduces battery cover weight by more than half compared to traditional steel shell materials. As a non-metallic material, the Baypreg® battery cover inherently offers superior anti-corrosion and insulation properties, effectively preventing electric arcing. When compared with non-metallic options, it outperforms in terms of surface smoothness and airtightness. It also demonstrates high strength meeting tough requirements from OEMs.

“As the inventor of polyurethanes, Covestro brings decades of expertise in the automotive industry, with PU solutions enhancing both driving and riding experiences in automotive interiors and exteriors. We can now extend this expertise to NEVs as well,” said Akhil Singhania, Global Head of PU Specialties at Tailored Urethanes, Covestro. “The Baypreg® STM solution showcases Covestro’s ability to deeply understand evolving market needs and rapidly innovate cutting-edge material solutions. Our goal is to deliver lighter, more efficient, and sustainable solutions through continuous technological innovation.”

The NEV industry has witnessed rapid growth in recent years. According to the China Passenger Car Association, NEV sales accounted for 51 percent of total passenger car deliveries in China in July 2024, outnumbering those of internal combustion engine vehicles for the first time.

Diverse applications for Covestro’s PU composites

At the CCE, Covestro will also showcase its PU composite solutions across various sectors. For instance, PU composites are widely utilized in photovoltaic (PV) modules to enhance efficiency and quality. Specifically, PU frames combined with coatings solutions from Covestro offer superior corrosion and weather resistance for PV modules, PU profiles excel in insulation and mechanical performance in energy storage batteries, and transparent front sheets based on composites enable high light transmittance while demonstrating exceptional strength for solar panels. 

Additionally, in construction, PU windows and doors are ideal for nearly zero-energy buildings due to their excellent insulation. In infrastructure projects, PU composites are widely used in power poles, railway sleepers and cable trays for their durability, weather resistance and low maintenance costs.

To learn more about Covestro's PU composite applications at the China Composites Expo, visit the company’s booth 7R19 in Hall 7.1 at the National Exhibition and Convention Center (Shanghai) from September 2 to 4, 2024.

The film documents the development of the innovative solar racing car “Covestro Adelie” and the participation of the team of around 50 students in the Bridgestone Solar World Challenge 2023 in the Australian outback. Using state-of-the-art technology and innovative high-performance materials from Covestro, the students have designed an energy-efficient and environmentally friendly racing car. The solar racer paves the way for the development of environmentally friendly vehicle technologies.

From design to the race track

The documentary follows Team Sonnenwagen from the design of the “Covestro Adelie” through to qualifying and then the race across Australia. In addition to the technical aspects of the racing car, the documentary also focuses on the emotions, challenges and tireless team spirit behind this ambitious project. In addition to the interviews with the dedicated students, numerous experts also have their say, including the renowned science journalist Ranga Yogeshwar, the Minister for the Environment, Nature Conservation and Transport in NRW, Oliver Krischer, the former Opel boss and CEO of Continental, Dr. Karl-Thomas Neumann, and Sucheta Govil from Covestro.

Available online on YouTube

“We are extremely proud that there is a documentary about our team and the great work of the past two years. This project is so important because it can play a small part in solving an important sustainability problem - greenhouse gas-neutral mobility,” says Sonnenwagen team leader Leonie Brandt.

The documentary “SONNENWAGEN - Future Mobility” will be available online on Team Sonnenwagen's YouTube channel from August 27, 2024 at 6:15 p.m. The trailer is already available HERE.

The automotive supplier Webasto has developed the prototype of a Roof Sensor Module (RSM) in an elegant design. It is equipped with a polycarbonate panel for aesthetic and seamless integration of sensors for automated and autonomous driving. For the module’s bezel, Covestro supported with its injection molding expertise at the technical center at its Headquarters in Leverkusen.

The bezel is produced on Covestro's 2300-ton injection molding machine. The first shot is made of the transparent polycarbonate Makrolon^® AG, which is highly permeable to various sensor signals. For the second shot, the black, mineral-reinforced PC-ABS Bayblend^® T95 MF is used. Thanks to the combination of both materials, the roof module meets high mechanical requirements while offering an attractive design with glass-like surfaces and transparent sensor windows.

Integration of components and coating

In addition, the combination of these materials provides the necessary design freedom for the integration of all relevant electronic and mechanical components. Many of such parts are furthermore attached by elements that are formed in the second shot. Suitable potential coating systems for the RSM are polysiloxane coatings, which are sprayed via a high-speed rotary bell to ensure homogeneous layer thicknesses over the entire component surface.

In use, radar and lidar sensors, as well as cameras, measure the distance and speed of objects in front of and next to the vehicle and also reliably detect traffic lights, traffic signs and road markings. In order to function optimally, the temperature of the electronics must be regulated. This is ensured by an integrated thermal management system. The high heat deflection resistance of polycarbonate ensures that the roof module remains in shape even at high outside temperatures and strong sunlight and that the functionality of the sensors is not impaired.

The Makrofol^® ST polycarbonate film, which is introduced in specific sections and is characterized by a defined transmission spectrum in the visible and infrared range, enables a seamless design with high transparency for LiDAR signals. In addition, the film serves as a carrier for Canatu's transparent heating system. This de-icing function as well as the specially developed cleaning system ensure flawless operation even under adverse weather conditions.

All in all, this development offers not only a portfolio of engineering solutions, but also concepts for developers of advanced driver assistance systems (ADAS) who need reliable and cost-effective bezels for their 3D imaging systems.

At the international VDI Congress PIAE on June 19 and 20, 2024 in Mannheim, Germany, Covestro expert Christoph Klinkenberg and Head of Research and Development Magnus Sviberg from Webasto Roof & Components SE will give a presentation on this development on June 19 from 12:15 p.m. The co-author is Rainer Hagen from Covestro. The company will also be exhibiting at the accompanying exhibition.

“Circularity requires cooperation, and this cooperation with our partners Neste and Borealis is testament to the possibilities at our disposal,” says Guido Naberfeld, Senior Vice President, Head of Sales and Market Development Mobility at Covestro. “We are creating options to turn old tires into new car parts again. With that, we are supporting our automotive customers and addressing an increasingly prominent question discussed across the value chain: How to match high-performance materials with recycled content? Projects like this can be the answer.”

As part of the collaboration, Neste turns liquefied discarded tires into a high-quality raw material for polymers and chemicals manufacturing and supplies it to Borealis. Borealis will then process the Neste-produced raw material into base chemicals phenol and acetone, which are supplied to Covestro. Covestro can use these materials to make polycarbonates. The share of recycled content is attributed via the mass balancing approach all the way to the final products using ISCC Plus certification.

The first products based on the collaboration are already available as each party has manufactured the first batch of their respective contribution to the project. Aside from polycarbonates, the project partners may also consider polyurethanes as a possible end product, which could also find its way into parts of the interior of a car. The companies emphasize that the potential to scale-up these types of developments should be considered when setting ambitious targets for future EU regulations, such as the End of Life Vehicles Regulation.

“We are demonstrating the importance of value chain cooperation to give new value to waste,” says Thomas Van De Velde, Senior Vice President Base Chemicals at Borealis. “We are proud that Borealis, in collaboration with Neste, is able to play a role in this project, providing more sustainable solutions for polymer applications for Covestro and its customers.”

“This project can serve as a blueprint when it comes to establishing circularity in the field of plastics in cars,” says Jeroen Verhoeven, Vice President Value Chain Development for polymers and chemicals at Neste. “It shows how low-quality waste materials can be turned into very high-quality plastics. This is good news for the polymers and automotive industries as well as for the environment.”

The collaboration will be presented during the PIAE in Mannheim on June 19-20, 2024.

Under a joint pilot program initiated by German federal enterprise GIZ (Deutsche Gesellschaft für Internationale Zusammenarbeit), Covestro and partners will collaborate to establish closed-loop pathways for high-value plastics from end-of-life vehicles (ELVs). The goal is to create an efficient and sustainable automotive plastic recycling system, advancing the more sustainable “transformation of the industry”. The pilot program was announced at Covestro’s booth during the CHINAPLAS 2024 international trade fair in Shanghai. Notable partners include leading automotive brand owners such as NIO of China and Volkswagen, Chinese recycling company GEM, and third-party certification bodies like TÜV Rheinland.

"We are proud to partner with like-minded value chain allies to pioneer closed-loop plastic recycling in the automotive sector," said Lily Wang, Global Head of the Engineering Plastics Business Entity at Covestro. "By leveraging our collective strengths and resources, we are confident in our ability to build a closed-loop for automotive plastics recycling, thereby reducing waste and carbon emissions at the source while improving resource use efficiency. Through this joint program, we aim to expedite the automotive industry’s transition toward a more climate-neutral and sustainable future."

"The automotive industry stands as one of the most resource-intensive sectors globally, yet the potential of high-value plastics from ELVs remain largely untapped," said Martin Hofmann, Cluster Head in charge of Climate, Energy, Environment and Biodiversity at GIZ. "GIZ is steering an innovative endeavor to explore closed-loop pathways for high-value plastics from ELVs. I firmly believe that GIZ and our partners can forge a path towards the transition to a sustainable, circular economy."

As part of the pilot program, a team of professionals will explore methods to recycle and process waste polycarbonate components, such as end-of-life car headlights, into post-consumer recycled (PCR) polycarbonates. The recycled materials will then be reused for various interior and exterior vehicle applications, saving resources and reducing carbon emissions.

This could offer urgently needed long-term solutions for the automotive manufacturing industry, which seeks high-quality PCR materials that are compliant and high-performance amid increasingly stringent regulations. For example, in 2023, the European Commission proposed a new regulation to enhance the circularity of the automotive sector, mandating that 25 percent of the plastics used in a new vehicle must come from recycling, of which 25 percent must be recycled from end-of-life vehicles.

Covestro will also be showcasing more solutions for the automotive industry at its booth at the CHINAPLAS 2024, such as an intelligent front grill and mono-material polycarbonate headlamp that are designed for a connected and circular future.

For a closer look at Covestro’s solutions at the CHINAPLAS 2024, visit the company at booth 7.2-C38, at the National Exhibition and Convention Center (Shanghai) from April 23 to 26, 2024.

Initial market engagement with automotive brand owners for a serial application of a high-purity polycarbonate is promising, it would represent having a transparent polycarbonate attributed with chemically recycled raw materials.

"We are very excited to expand our existing portfolio of more sustainable polycarbonates with this new product range, which marks another milestone in building the circular economy," explains Lily Wang, Global Head of the Engineering Plastics Business Entity at Covestro. "Together with our partners, we are already helping to conserve fossil resources and to give a second life to existing waste streams. We also support our customers in achieving their sustainability goals by providing materials that meet the highest purity standards."

Recycled raw materials in trend

More and more industries are asking for products with a specific proportion of recycled raw materials, also in the expectation of upcoming regulatory requirements or voluntary programs, such as the European End-of-Life Vehicle Directive under review (ELV) and the U.S. Electronic Product Environmental Assessment Tool (EPEAT) for electronics products. The RP series offers identical quality as incumbent fossil grades and belong to Covestro's CQ family. The company uses this suffix to identify products that contain at least 25 percent alternative raw materials. At certain sites, such as Krefeld-Uerdingen in Germany, the plastics in the new range are also produced exclusively using renewable electricity.

The input for Makrolon^® RP is provided by Neste and Borealis: Neste provides high-quality recycled feedstock for new polymers, which is then turned into phenol and acetone by Borealis before it finds its way to Covestro’s site to produce Makrolon^® RP.

"Through chemical recycling, we can enable recycled content even for the most demanding applications," says Jeroen Verhoeven, Vice President Value Chain Development for Neste’s polymers and chemicals business. "Therewith, we can help companies across various sectors to achieve their recycling-related targets – and we are excited to see Covestro put it into motion."

"Borealis is very happy to support Covestro in this important initiative – helping to provide credible sustainable solutions and demonstrating the importance of value chain cooperation to give new value to waste," says Thomas Van De Velde, Borealis Senior Vice President Base Chemicals.

In addition to applications in the automotive industry, Covestro also wants to address other key industries such as the electrical & electronics and the healthcare industry. The aim is to manufacture high-quality and durable products with chemically recycled attributed feedstocks. At the end of a long usage phase, the plastics can still achieve a "third product life" through mechanical recycling and the further development of chemical recycling technologies.

The new series complements Covestro's existing portfolio of more sustainable polycarbonates – the mechanically recycled Makrolon^® R products and certified mass-balanced grades of the Makrolon^® RE series, which are produced using biowaste and bio-residues. The RE series are now also available with 25 percent renewable attributed sustainable share.

The first applications for the new grades could be in the electrical and electronics industry, as well as in healthcare. Both sectors are particularly well represented in Asia. For their use in housing parts, plastics of the new Apec^® XT line must above all offer freedom of design, dimensional stability, impact as well as chemical resistance and, in some cases, good flame retardancy.

There are also promising prospects for the copolymers in telecommunications and photovoltaics, for example in antenna housings, where weather-resistant, electrically insulating, ductile and flame-retardant materials are needed.

Further product innovations based on the new copolymer technology platform could focus on the automotive industry and infrastructure, where plastics from the new series have good prospects for use in housings for residential energy storage systems, charging stations and wall boxes, for example, thanks to their good electrical insulation properties, weather resistance and flame retardancy.

Apec^® XT grades will be designed to remain resilient even in the harshest conditions. The new copolymer technology enables the production of products that exhibit high impact strength even at temperatures as low as minus 40 degrees Celsius. In addition, these copolymers have improved chemical and ageing resistance, making them ideal for applications that require contact with aggressive cleaning agents and long durability in outdoor applications.

More sustainable products also available

APEC^® XT will also be part of the Covestro CQ portfolio of more sustainable product solutions. In that regard, Covestro will offer copolymer-based products in a version with up to 80 percent of ISCC PLUS-certified mass-balanced raw materials attributed from biowaste and bio-residues.

In addition, the company will offer products that incorporate recycled materials in order to also further reduce its environmental footprint. Moreover, due to its superior weatherability performance, the extended service life of APEC^® XT based products will improve product carbon footprint over its entire life cycle.

The advantages are obvious: customers do not need to invest in expensive prototype tools and replacement materials or in complex color matching processes. Covestro expects that initial sampling loops can be carried out completely virtually to a certain extent – this saves time and material resources. In future, the company will offer all services related to sampling under the Imagio^® CQ brand. The suffix "CQ" stands for Circular Intelligence and emphasizes that the technology makes its contribution to a circular economy in the form of significant material savings.

ʺOur strategy is to get in touch with our customers at an early stage of product design, when the first material specifications are being defined,ʺ explains Dr. Tobias Rausch, Business Development Digital Sampling in the Engineering Plastics business unit at Covestro and head of the project. ʺWe also want to facilitate collaboration between cross-site teams with new digital tools such as catalogs and material twins.ʺ

Faster and more efficient

Customers' product development requirements are constantly growing: they want to be flexible in their choice of materials and increasingly value a more sustainable origin. At the same time, they want to bring their products to market faster while increasing efficiency and saving costs. In addition, they often work in several teams across regions, which need to communicate effectively with each other and also exchange sample parts.

The optimal solution for these requirements is to involve Covestro and its Imagio^® CQ program at an early stage. This enables customers to make a material decision more quickly and generate and visually evaluate sample parts in the early stages of development. This saves time and costs during specification, and the suitability of more sustainable plastics can also be tested at an early stage. In the three-dimensional space of color, material and finish (CMF), the possibilities are almost unlimited.

The backbone of the digital solution is X-Rite/Pantone's Total Appearance Capture (TAC) technology, which captures optical properties such as color, gloss, transparency, translucency or texture of a specific material sample using an optical appearance measurement device. The data is stored in a special data format. This is supported by leading rendering software tools that Covestro customers use for their design and marketing visualization. Covestro's Color & Design Centers (CDCs) in Filago, Italy, Newark, USA, and the Caojing and Guangzhou facilities in China are already equipped with the technology to create digital twins of materials.

A new tool for sales and marketing to search for color combinations – the Imagio^® Color Finder (ICF) – also serves to achieve this goal. Overall, Covestro expects a shift from costly color matching requests in the CDCs to existing color codes with a better search experience.

The Imagio^® CQ family has now been expanded to include a module called Imagio^® Optical Material Data. The target group here are experts from the field of development and simulation of optical components, i.e. vehicle headlights and interior lighting, as well as general lighting. The module is already being tested with customers and will be the first Imagio^® module to be available after the required registration. On the one hand, it will be possible to search specifically for optical material properties in our EP portfolio, and on the other, Covestro will provide the necessary data for optical simulation programs such as Ansys Speos, Optis LightTools or customers' own simulation solutions.

"Covestro understands the value chain and is not only a film producer but also an innovator and integrator," says Karine Benbelaid, Global Head of Medical Segment, Specialty Films, Covestro. "The company has a long, successful track record driving industrial collaboration with converters, printers, OEMs, research labs and designers. We’re highlighting a few of these collaborations at LOPEC 2024."

Covestro is participating at LOPEC, the International Exhibition and Conference for Printed Electronics, in Munich, Germany from March 5-7 at Hall 0, Booth 612 (B0.612). The company will showcase a diverse range of polycarbonate (PC) films and thermoplastic polyurethane (TPU) films for printed electronics manufacturing in healthcare and HMI (human-machine interface) applications in automotive and electronics design.

Smart patches and other healthcare applications

In the healthcare sector, smart medical skin patches help improve patient comfort and allow for enhanced remote monitoring, such as Electromyogram (EMG). While electronic patches are already used in many areas, such as patient monitoring, there is a growing need for digitization. With this in mind, Covestro will display a smart patch for early detection of ostomy bag leaks, developed with Witte Technology GmbH and Lohmann GmbH & Co. KG.

People with artificial intestinal outlet (stoma) use ostomy bags, which collect the gut and bowel liquid. These bags can sometimes leak, which can be associated with discomfort for the patient. For that reason, early detection is crucial to patient comfort. Using a sensor array printed on a medical grade Platilon^® TPU film, the smart patch on display can detect any leakage between the artificial intestinal outlet and the ostomy bag. The patch is designed for retrofitting an ostomy bag and can be integrated into existing ostomy bag solutions.

"The excellent collaboration among Witte Technology, Lohmann, and Covestro has yielded a groundbreaking solution: a smart patch for early ostomy bag leakage detection," says Dr. Volker Lutz, Head of New Business Development, Lohmann GmbH & Co. KG. "With its innovative sensor array on medical-grade Platilon^® TPU film, this smart patch promises enhanced comfort and peace of mind for ostomy patients around the world."

The following applications are also on display:

• Smart EMG wearable patches for biosignal acquisition made with Platilon^® 5302 MR7X, courtesy of Nile AB (Linxens Healthcare)
• Platilon^® TPU films with excellent printability for silver-based inks, which ensure high conductivity

HMI for automotive and electronics applications

LOPEC attendees will also see HMI applications for automotive and electronics designs enabled by in-mold electronics (IME). The feasibility of these technologies for mass production will be demonstrated using examples of the design of intelligent surfaces and innovative lighting.

The ´smart surface´ demo, jointly developed by Covestro and TactoTek^®, will demonstrate the use of Makrolon^® polycarbonate resin and Makrofol^® PC film technology to bring electronics into thin, durable and seamless 3D plastic surfaces by Film Insert Molding (FIM) technology.

An innovative lighting project for surfaces called ‘Jenny’ will also be on display. Jenny was developed by TactoTek^® and Novem using Covestro materials and consists of real wood laminate and areas of triangular PC overmolds and wood. This structure provides seamless, even lighting in a high-quality design.

"We are thrilled to reveal ‘Jenny’, our extraordinary lighting concept. The A-Surface can be customized for an ultra-premium feel and finish", says Paavo Niskala, SVP IMSE Technology, TactoTek^®. "By integrating Makrofol^® and Makrolon^® layers, along with different surfaces, we have achieved an unparalleled fusion of innovation and elegance."

At LOPEC 2024, Covestro will display a LiDAR cover lens, engineered with Canatu, featuring Makrolon^® AG polycarbonate resin and Makrofol^® PC film with an integrated heater. This collaboration enhances Light detection and ranging (LiDAR) systems for modern vehicles, ensuring reliability in harsh weather by combining Covestro's thermoplastics expertise with Canatu's carbon nanotube (CNT) transparent film heater.

Hear from a Covestro expert

At LOPEC 2024 Congress, Covestro expert Karine Benbelaid will give a lecture on March 5, room 13b at 9:05 a.m. CET, entitled, “Turning Medical Devices Smart and Circular".

Building upon previous sustainable sourcing efforts, this marks the first major procurement agreement involving chemically recycled, circular-based raw materials for Covestro, a major step in the company’s journey towards full circularity. It also helps reduce scope 3 emissions for Covestro and its customers.

"The ability to source raw materials from used plastics for the manufacture of our products makes a decisive contribution to realizing our vision of a circular economy," said Thorsten Dreier, Chief Technology Officer at Covestro. "This is because such raw materials not only enable the reuse of used plastics, but also have a lower carbon footprint, which leads to more sustainable end products."

Benzene and toluene are important raw materials in Covestro’s manufacturing processes used for the production of methylene diphenyl diisocyanate (MDI) and toluene diisocyanate (TDI), respectively. MDI and TDI are critical raw materials used to produce rigid and flexible polyurethane foams, which are used in applications such as household appliance and building insulation as well as furniture and car seats.

Benzene can also be used for the synthesis of phenol and acetone – raw materials for making polycarbonate plastics such as Makrolon^®, which are used in high-quality applications for the automotive, electronics, IT and other industries.

Encina’s proven proprietary catalytic technology produces circular feedstock with a lower carbon footprint when compared to those based on fossil fuels and an exceptionally high yield.

"Encina is proud to be working with Covestro, a company with a long track record of innovation and commitment to sustainability. This agreement represents the beginning of what we hope to be a long-standing partnership between our companies as we work to create a truly circular economy and realize a future in which nothing is wasted," said David Roesser, Chief Executive Officer of Encina.

Covestro’s vision to become fully circular is predicated on four key drivers: the use of alternative raw materials, innovative recycling and renewable energy, as well as engaging in joint solutions. The agreement with Encina represents a pioneering milestone for incorporating innovative recycling technologies, in this case chemical recycling of end-of-life plastic, into Covestro’s production.

Covestro is already making an important contribution to more sustainable vehicles and infrastructure with innovative material solutions. In this context, the company is also working in close partnership with Team Sonnenwagen, a team of around 50 students from RWTH Aachen University and Aachen University of Applied Sciences. It is dedicated to developing racing cars that are powered solely by the sun. Covestro shares the students' enthusiasm because the racing cars, with their high efficiency and use of new technologies and materials, are a powerful symbol of the mobility of the future. That is why Covestro is supporting the team as the main sponsor with material solutions and technical exchange for another two years.

"In order to create a climate-neutral and circular mobility of the future, business, politics and society must pull together. At Covestro, we are contributing to this transformation by offering the automotive industry raw materials based on biomass or recyclates and manufacturing our products as energy-efficiently and with as few emissions as possible," said Dr. Thorsten Dreier, Chief Technology Officer, during the discussion. "At Covestro, we want our production to be climate-neutral by 2035 and are relying on energy from renewable sources and innovative process technologies to achieve this."

Covestro's material developments focus on solutions for the major trends of electromobility, autonomous driving and the need for individualization. These include material solutions for compact, powerful and safe batteries for electric cars and robust charging systems, plastics for connected mobility and the Internet of Things, as well as various products for aesthetic and functional automotive interiors and exteriors.

Covestro has been supporting Team Sonnenwagen in the development of ever more efficient solar racing cars since 2017. The students are working together in a wide range of disciplines to improve the aerodynamics, optimize the chassis and install a particularly efficient photovoltaic system and battery. Participants at the NRW Mobility Day were able to take a look at the Covestro Photon, the predecessor model to the current Adelie racing car, and talk to team members. With the Photon, Team Sonnenwagen became European champion at the European solar race in Zolder, Belgium, in September 2022.

Since the new dispersion has the same outstanding properties as the established one, as well as a high solids content of 55 percent, customers can now replace Impranil^® DLU one-to-one with Impranil^® CQ DLU in their processing operations – and thereby easily achieve an additional increase in textile coating sustainability. Sustainability is increasingly becoming a key purchasing criterion not only for the industry, but also for brand owners and consumers. CQ stands for "Circular Intelligence". The core idea of the CQ concept is to label Covestro products if the alternative raw material base exceeds a content of 25 percent, as in this case.

As the raw material for INSQIN^® technology, the established Impranil^® DLU already enables aqueous textile coating without the use of solvents. The ecological footprint of such a coating is significantly lower than that of solvent-based systems. "With the innovation Impranil^® CQ DLU as part of our Impranil^® CQ portfolio, we are now enabling the textile coatings industry to take the next step towards more sustainability through the increased use of renewable resources," says Dr. Torsten Pohl, Head of Global Textile Coatings at Covestro.

Impranil^® CQ DLU is suitable, among other things, for producing synthetic materials for sports articles, technical textiles, car interiors, and bags. Properties of coatings based on the new high-performance dispersion include excellent hydrolysis resistance, very good lightfastness, as well as high tensile strength and scratch resistance. In addition, the coatings have a pleasant feel and good alkali resistance. Impranil^® CQ DLU can be used for both the intermediate coat and the top coat. The dispersion can be applied in various ways: The spectrum ranges from direct or transfer coating to printing processes and microfiber dipping.

Visit us at the Automotive Interiors Expo

From December 5 to 7, 2023, visitors to the Automotive Interiors Expo in Stuttgart can explore the new PU dispersion for themselves: A car interior door panel coated with Impranil^® CQ DLU will be demonstrated at the Covestro exhibition stand no. 3424 in Hall 3.

Joining forces for global automotive advancement

Covestro excels in offering a diverse array of solutions for the automotive industry. Polyurethane, invented by Otto Bayer at Covestro’s predecessor company Bayer, is the vital material for automotive interiors. Polyurethane-based automotive interior applications, such as instrument panels, door panels, and center armrests, offer a soft, tactile feel, enhancing the comfort of both drivers and passengers. Polyurethane materials are known for their lightweight properties, minimal odor, and low levels of volatile organic compounds. These attributes create a comfortable and environmentally compatible interior environment, answering key demands of the automotive industry.

Having cultivated a successful cooperation with Xinquan for ten years, Covestro possesses a deep understanding of the evolving requirements of Chinese enterprises striving to expand their global presence. Xinquan’s global expansion strategy involves localizing research, production, and sales, in the respective regions. Its plant in Mexico has already started production last year, and there are plans for a North American technical center along with new facilities in Europe and ASEAN.

Covestro is well-equipped to effectively support Xinquan’s global aspirations. With its focus on innovation and research, Covestro has established ten innovation hubs across America, Asia and Europe. Furthermore, Covestro operates production facilities in Mexico and the U.S., where they have delivered polyurethanes to Xinquan’s new plant in Mexico. The partnership exemplifies the effectiveness of globalization in driving innovation and highlights Covestro’s commitment to globalization and expanding its presence in key markets.

"Covestro thrives on dynamic global partnerships, fueling innovation and tailoring solutions for the automotive industry. Together, we power our customers’ global expansion and zero-carbon journey. At Covestro, customer centricity isn’t just a phrase – it’s our energizing force, creating unmatched value through vibrant collaborations," said Christine Bryant, Head of the Tailored Urethanes Business Entity at Covestro.

Low-carbon polyurethane solutions for auto interiors and new energy vehicles

Expanding their technical collaboration, Covestro and Xinquan will harness Covestro’s global R&D capabilities to develop low-carbon polyurethane solutions for vehicle interiors by using partially bio-based raw materials. Besides, the cooperation extends to the development of polyurethane applications for electric vehicle battery packs. This partnership is intended to assist the automotive industry in attaining its carbon reduction objectives and embracing circular economic practices.

"During Xinquan’s global expansion, we have worked with Covestro closely to share resources and complementary advantages. By improving production efficiency and quality, reducing costs and risks, Xinquan has strengthened its core competitiveness," said Zhihua Tang, Chairman of Xinquan. "With this new global partnership, we will jointly promote technological innovation and low-carbon applications of polyurethane materials to advance the sustainable development in the automobile industry."

For a closer look at Covestro’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

As automobile technology continues to progress in areas like integration, intelligence, electrification and data connectivity, the importance of displays as an interface for human-vehicle interaction is growing. Manufacturers not only need to ensure the reliability of these displays but offer flexibility in design to accommodate the rapid changes in new energy vehicles. In response, Covestro has teamed up with CTOT, a leading manufacturer of backlight modules, to explore tangible solutions.

Since this year, the partnership has led to the release of Makrofol^® LM807, a high-quality PC light guide plate material designed for vehicle displays. Made with optically graded materials and processed with precision, Makrofol^® PC films demonstrate excellent optical and physical properties along with consistent quality. These features enable light guide plates to accommodate larger and thinner screens. This aligns with the growing trend for expansive displays in electric vehicles, thereby enriching user experiences in both intelligence and entertainment. An initial order of 20 tons of Makrofol^® LM807 has been placed by CTOT.

Enhanced partnership

The latest strategic agreement will further consolidate the partnership between the two companies and expand their joint efforts into high-end industrial control displays. The goal is to provide display module manufacturers with high-performance, flexible, and efficient solutions.

During the signing ceremony, Dr. Caroline Wolff, head of Specialty Films in the Asia-Pacific region at Covestro, said, “Covestro is committed to providing high-quality products and continually looks for the best application scenarios. Improving user experience remains a key focus of our efforts at Specialty Films. This partnership marks a comprehensive strategic collaboration in the field of vehicle displays, and we look forward to collaborating with like-minded companies such as CTOT to further industry development.”

Yao Bin, general manager of CTOT said, “CTOT is dedicated to offering clients enhanced experiences and diverse choices. Our partnership with Covestro stands as a model, encouraging the industry towards the adoption of innovative technologies. In collaboration with Covestro, we aim to shape the future of vehicle displays.”

For a closer look at Covestro’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

The joint lab will mainly focus on the commercialization of low-carbon material solutions in future EV models and the establishment of relevant standards, as well as the development of next-generation smart surface technologies and battery solutions. This initiative builds upon a cooperation agreement signed between the two companies at the CIIE last year.

"We’re delighted to deepen our collaboration with HiPhi," said Dr. Markus Steilemann, CEO of Covestro, during the unveiling ceremony at Covestro’s booth at the CIIE. "We set out to address the key challenges of future mobility with the launch of the joint lab. With our common commitment to pioneering low-carbon smart mobility and by combining our strengths and resources, we believe the lab will accelerate the automotive industry’s transformation towards a smarter and climate-neutral future."

"HiPhi aims to redefine the luxury brand in the new era. We are accelerating the adoption of intelligent and low-carbon technology in smart EVs to provide global users with a safe, efficient and sustainable travel experience, thereby changing the future of mobility and contributing to society," said David Ding, Founder and CEO of HiPhi. “Covestro’s advanced material expertise is key to helping us achieve this vision. The establishment of our joint laboratory stems from Covestro’s recognition of the innovative strength represented by HiPhi and other Chinese companies. We also aspire to empower our global partners and foster mutually beneficial relations through the CIIE.”

On display at Covestro’s booth at the CIIE is the HiPhi Y, the latest luxury SUV that incorporates advanced polycarbonate solutions from Covestro, most notably in the headlamp and LiDAR lenses. As EV becomes increasingly smarter, the headlamp presents new opportunities in digital communication beyond lighting. On the HiPhi Y, the headlamp lenses are turned into a projector to display signs and patterns in front of the vehicle, creating an interactive interface with pedestrians and other vehicles. Covestro’s high optical performance Makrolon^® AL solutions offer the needed dimensional stability, UV resistance and high transparency required for this application. In the LiDAR lenses, the Makrolon^® AX portfolio demonstrates superior performance compared to glass, including excellent infrared transmittance, shaping curved surfaces and impact resistance against stone chips. They can also endure the working environment of LiDAR at temperatures from 110 to 115 degrees Celsius for extended periods.

"As the mobility industry embarks on a journey towards carbon neutrality, the demand for circular, low-carbon footprint materials is growing rapidly and will only accelerate in the near future," said Lily Wang, President of the Engineering Plastics segment at Covestro. "We hope to collaborate with more like-minded companies, like HiPhi, to accelerate the decarbonization trend and pioneer smart technology development at the same time."

HiPhi has been a long-term partner of Covestro since 2018. Covestro’s material solutions have been applied to HiPhi’s flagship models, such as the polycarbonate solutions that enable a "smart" B-pillar equipped with complex functions in the all-electric SUV HiPhi X. HiPhi Z, a smart sports sedan, employs polycarbonate grades for the touchpad switch on its steering wheel – enabling a futuristic interactive design – as well as high performance waterborne polyurethane adhesives for auto interiors.

For a closer look at Covestro’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

“In the face of global challenges such as climate change, innovative materials like plastics are needed more than ever to drive progress towards a truly sustainable future ,” says Dr. Markus Steilemann, CEO of Covestro. “China, with its ambitious climate targets, is a leader in dynamic markets like electric vehicles and renewable energy. We are eager to contribute our material expertise to aid the nation’s transition, while driving fresh business momentum.”

Under the banner of “Becoming Fully Circular and Climate Neutral,” Covestro’s CIIE booth features dedicated areas, including “Beyond Mobility”, “Green Home”, “Renewable Energy” and “Fully Circular”. Several showcases will highlight the pivotal role of sustainable materials in these sectors. Additionally, a dedicated “Covestro Story” area shall engage visitors, particularly those outside the chemical industry.

Chemical recycling of polyurethane foams

The “Fully Circular” zone will for example demonstrate advancements in recycling technologies and in the use of alternative raw materials. Notably, it will showcase a recycled foam created through Covestro’s proprietary chemical recycling process. This groundbreaking process is capable of transforming end-of-life mattress foam directly into its core building blocks, breathing new life into old foam.

At the center of “Beyond Mobility” stands Chinese EV maker HiPhi’s latest luxury SUV – the HiPhi Y. It extensively incorporates Covestro’s advanced and sustainable material solutions in interior and exterior components. This includes the use of high optical performance polycarbonate in LiDAR lenses, taking advantage of the material’s temperature resistance up to 115 degrees Celsius along with its excellent infrared transmittance, ensuring the reliable and stable operation of the entire system. The strengthened partnership builds upon a cooperation agreement signed between the two sides at last year’s CIIE.

Covestro also aims to foster collaborations for ultra-low energy buildings (ULEB). The company’s materials can support making buildings more energy efficient and causing less emissions – key to the sector, which is one of the major contributors of global emissions. Covestro will for example show polyurethane pultrusion composites for window frames, and highly efficient building insulation solutions at the “Green Home” zone. At this year’s CIIE, the German materials manufacturer will sign agreements with Chinese real estate developers and value chain partners, forming multi-party business collaborations in this vital domain to expedite the adoption of sustainable solutions.

“The CIIE has consistently proven to be a highly rewarding endeavor for Covestro. It offers a unique platform to strengthen partnerships and promote our approach to becoming circular and how we can support downstream industries to do the same,” says Holly Lei, president of Covestro China. “We are committed to delivering versatile solutions and exploring innovative business models in collaboration with value chain partners both within and beyond the CIIE venue, in support of China’s sustainable development.”

The CIIE stands as the world’s first national-level import-themed exhibition, an annual event since 2018. This year, it draws over 3,400 international exhibitors and is expected to host hundreds of thousands of visitors. The CIIE serves as a platform that fosters international procurement, investment promotion, cultural exchange, and open cooperation. China’s ambitious climate goals, including reaching peak carbon emissions by 2030 and attaining carbon neutrality by 2060, carry global significance to meet the Paris’ agreement and remain a consistent focal point in the exhibits and activities at the CIIE.

For a closer look at Covestro’s solutions for a fully circular future at the CIIE, visit us at booth 3B6-05, at the National Exhibition and Convention Center (Shanghai) from November 5 to 10, 2023.

"For me, Team Sonnenwagen had already won even before the race! Team Sonnenwagen had captured the hearts and minds and the collective enthusiasm of all Covestro employees around the globe," says Sucheta Govil, Chief Commercial Officer of Covestro. "The team grabbed its rightful first place in qualifying and set its sights on victory from the start from pole position. The Covestro team was integral in its support. Yes, support to the students via innovative material developments but also fully involved throughout the race. And the Aachen-based team did its part: With their efficient car design and sophisticated driving performance, they led from the very front in performance, in design and in resilience, guts and stamina. I'm very proud of the team!"

"Of course, risk always rides along, especially if you want to achieve a top position," says Simon Zaers from Team Sonnenwagen. “Nevertheless, our intensive development work of around two years really paid off, especially because we also attached importance to a safe design. It played its part in ensuring that no one was injured in the accident. We were also able to gain a lot of valuable experience for the construction of our next solar runabout, with which we would like to participate in the World Solar Challenge 2025. Together with the other teams, we continue to pursue our goal of enabling more sustainable mobility with innovative designs – powered only by the power of the sun.”

Covestro shares the enthusiasm of the Aachen team and has been supporting it as a main sponsor for around five years. The company is convinced that high-performance plastics are the key to climate-neutral and circular mobility in the future, and is working with customers and partners to develop material innovations and new recycling technologies to achieve this.

Covestro also believes that the 50-strong Sonnenwagen team is on the right track in terms of cooperation: from development and design to the race itself, nine departments worked closely together to optimize aerodynamics and electrical engineering, the chassis, the powertrain and, not least, the driving strategy. The result after more than 200,000 hours of calculations for the outer shape and around 10,000 workshop hours for the body is impressive – and weighs a lot: the structure of the Adelie weighs in at 16 percent less than its predecessor, and the chassis even weighs a fifth less. These improvements are also due to materials from Covestro.

"After the race is before the race," sums up Lina Schwering, 1st Chairwoman of Team Sonnenwagen. "We will also learn from this competition and continue to optimize our design with a partially new team, just as the other teams are doing. There are very many parameters on whose interaction the race will be decided, and consistency and the will to consistently learn from experience will ultimately lead to the goal. However, this race has also shown us that in the end it also depends on a certain quantum of luck."

"The launch of our MCR production line marks another significant stride in our journey towards achieving a circular economy and operational climate neutrality by 2035," said Sucheta Govil, Chief Commercial Officer of Covestro. "Plastic waste recycling is pivotal in realizing this vision, and through the expansion of our recycled plastics production capacity, we aim to lead the way in driving sustainability across diverse industries."

Covestro is committed to supplying over 60,000 tons of recycled-content polycarbonates annually in the Asia Pacific region by 2026, in response to robust market demand. Recently, the company also transformed an existing compounding line at its Map Ta Phut site in Thailand for mechanically recycled polycarbonate.

"These investments enable us to meet the rising demand for PCR polycarbonates, enhancing our capacity and efficiency. With new or repurposed capacity now operational, we are better positioned to assist our downstream customers in their journey towards more sustainable products, expediting the transformation of industries towards a circular and climate-neutral future," said Lily Wang, Head of Covestro’s Business Entity Engineering Plastics.

A broad range of PCR portfolio

The demand for such materials is surging on a global scale, driven by regulatory initiatives like the European Union’s proposed Directive on end-of-life vehicles (ELV Directive), which sets strict benchmarks for the utilization of recycled plastics. Furthermore, industries like consumer electronics are poised for increased demand for recycled materials, especially those with a substantial recycled content.

These market dynamics underscore the significance of Covestro’s recent developments in providing PCR polycarbonates. Earlier this year, the company unveiled a polycarbonate boasting 90 percent recycled content. This grade not only attains outstanding whiteness and highly saturated colors but also touts a sustainable feature – a 70 percent reduction in carbon footprint compared to its fossil-based virgin plastic counterpart. Achieving this remarkable accomplishment requires a meticulous selection of high-quality recycled materials and precise optimization of material composition during the compounding process.

Furthermore, Covestro is actively engaged in pioneering the chemical recycling of polycarbonates. Having successfully developed an innovative process within the laboratory, the company is now embarking on the technical implementation of this breakthrough at a pilot scale.

Expansion of polycarbonate production capacity in Asia Pacific

After debottlenecking multiple production lines at the Map Ta Phut site in Thailand, Covestro is nearing the final stages of a program to enhance polycarbonate production capacity and capabilities across the Asia-Pacific region. This program also includes the addition of new production lines at sites in Shanghai and Guangzhou, China, as well as Greater Noida, India, in recent times. The combined additional capacity now exceeds 100,000 metric tons annually. These strategic projects, aimed at optimizing the regional production network, have been supported by using digital tools, which also reduced investment costs.

"In this way, we aim not only to meet the growing demand for polycarbonate in Asia, but also to offer our customers there an improved product quality," says Dr. Nicolas Stoeckel, Head of Operations in the Business Entity Engineering Plastics. "Depending on demand, the upgrades can be used for compounding recycled or conventionally produced polycarbonate." Therefore, both projects are also about improving Covestro´s ability to produce more plastics with higher recycled content.
 

This site of Epurex Films, a wholly owned subsidiary of Covestro, houses research & development, application development and production for the semi-finished products. The company has invested a low double-digit million Euro amount in the expansion of the center of excellence for TPU-Films.

The new capacity is intended to meet the growing global demand for multilayer TPU films. They are used in automotive interiors and construction, among other applications. Breathable, water-impermeable specialty films have also proven their worth in wound care and outdoor clothing.

"With this capacity expansion, we are strengthening our Bomlitz site and our position as a leading supplier of technical specialty films," said Dr. Thorsten Dreier, Covestro's Chief Technology Officer, at the inauguration. "At the same time, we are investing in promising technologies and applications and creating new jobs."

For Aleta Richards, global head of the Specialty Films business entity, the expansion offers opportunities to respond even better to individual customer needs and offer more sustainable products. "For some time now, we have also been developing customer-specific solutions with films made from alternative raw materials, as we are also seeing increasing demand in this area. The development and production of partially biobased products is therefore to become a new focus at the Bomlitz site."

Covestro is fully geared toward the circular economy and aims to become climate-neutral by 2035. In 2022 the Bomlitz site has switched its power supply completely to green electricity. Epurex Films is one of Covestro's three competence centers for specialty films in Germany, along with Leverkusen and Dormagen.

TPU is a versatile plastic material used in a variety of applications such as sports shoes, IT devices such as sweepers, smart speakers, phone cases, automotive applications like paint protection film or for the protection of wind turbine blades.

"We are excited to announce that the construction on our new TPU site commences. It shows our commitment to strengthen our production network for our Solutions & Specialties business entities overall and for the TPU business in particular,” said Dr. Andrea Maier-Richter, Head of TPU at Covestro. “It reinforces our position as one of the leading global suppliers of TPU and puts us right where important value chains are."

Once completed, the site will span across 45,000 square meters. With its potential maximum capacity of up to 120,000 tons it will then also be Covestro’s largest TPU site worldwide.

"We are committed to working closely with our customers and partners," said Lisa Ketelsen, Head of TPU in APAC at Covestro. “As Guangdong province is a major hub for the IT, consumer electronics, footwear and other industries, we believe that locating our production in close proximity enables us to collaborate optimally. To underline that, an innovation center will be part of the next phase of our investment, enabling our researchers to design customized material formulas and do formula adjustments to meet customer demands within very short cycles.”

The new TPU site will enable Covestro to provide high-performance yet sustainable solutions to its customers faster and more flexibly. At the new site in Zhuhai, Covestro shall to that end eventually offer products with the label “CQ”. Products labelled as such consist of at least 25 percent alternative, non-fossil raw materials. The site will also utilize the most advanced production technologies and be run on 100 percent renewable power.

“Together with recent investments in new plants for Elastomers, Polyurethane Dispersions and a production line for the mechanical recycling of polycarbonates in our site on the outskirts of Shanghai, this new site for TPU in southern China shall capture the robust growth of the core industries served by our Solutions & Specialties business entities in China, the region and worldwide,” said Holly Lei, President of Covestro in China.

Offering sustainable and ever more circular solutions are among the long-term core targets for Covestro overall and for the new TPU site. The company for that purpose in general works on broadening the raw material base for its products, using ever less crude oil and its derivatives. It works on using recycled materials and can also already offer core materials with attributed alternative raw materials (such as biomass) via the mass balancing approach. Besides using less fossil-based raw materials, the company also want to use clean energy sources to run its plants and manufacturing processes and aims at becoming operationally climate neutral by 2035. By the end of 2023, it expects to already cover 16 to 18 percent of its energy demand from renewable sources.