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.

During COMPUTEX 2026, Covestro held a seminar themed “Grab the development trend of material effects in AI era” and showcased its material solutions, drawing strong interest from industry attendees. The seminar highlighted how these innovations can power next-generation product development, particularly in AI data center servers, thermal management solutions and outdoor network equipment. 

"The Material Effect is not only about what materials can do in a product, but also about how material expertise can support customers across the innovation journey,” said Lily Wang, President of Engineering Plastics at Covestro. “By combining high-performance polycarbonates, sustainable material choices, application development and global supply capabilities, Covestro helps customers bring AI-era electronics from idea to scale." 

Strengthening AI Data Center Server Performance

As AI applications scale, the hardware systems behind computing power are facing more demanding operating conditions. In data centers and supercomputing servers, higher power density and more compact architectures are raising requirements for flame retardancy, thermal stability, structural strength and lightweight design. 

Within server and data-storage systems, components such as air ducts, HDD/SSD trays, front bezels and light guides must maintain tight tolerances within compact layouts while enduring repeated maintenance cycles. These demands call for materials that combine durability, flame retardancy, heat resistance and excellent processability. 

Covestro’s polycarbonate solutions help meet the requirements of demanding server applications while enabling thin-wall structures and complex geometries. With bio-circular attributed and post-consumer recycled (PCR) polycarbonates, Covestro also supports lower-carbon material choices for AI infrastructure while maintaining high performance. 

Unlocking Smarter Thermal Management

As AI-era electronics and connected devices become more powerful, compact and always-on, thermal management is becoming central to system performance and product design. 

Higher power density can create heat challenges within limited space, requiring materials that support heat dissipation while enabling lightweight and more integrated component designs. For applications such as next-generation Wi-Fi routers, Makrolon^® TC polycarbonate combines thermal management, dimensional stability, lightweighting and flame retardancy to help support compact thermal designs. 

Compared with metal heat sinks or multi-part thermal solutions, this material-based thermal management approach for electronic components can simplify production and finishing, helping optimize total cost while unlocking greater design potential. 

Extending Resilient Connectivity Outdoors

As AI-era applications place greater demands on connectivity, network infrastructure for telecommunications and connectivity is extending into more complex outdoor environments. Outdoor network equipment, including 5G base stations, satellite terminals and outdoor Wi-Fi devices, must maintain signal performance and device protection in harsh outdoor environments. 

Under extreme temperature fluctuations, especially in low-temperature conditions, traditional housings for network devices can become brittle and prone to fractures. Covestro’s low-temperature impact-resistant polycarbonate solutions help maintain stable signal transmission under extreme temperature fluctuations from -40°C to 85°C and in high-salt environments. 

With strong dimensional stability, stable dielectric performance across a wide range of high- and low-frequency bands and high resistance to solar radiation, these materials support durable device and antenna housings for harsh outdoor use, helping realize reliable, long-term operation in outdoor network and telecom applications. 
 

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.

Across modern football, materials play a role in helping enable speed, control, comfort, durability and reliable performance, from equipment and apparel to infrastructure and digital connectivity.

Covestro is highlighting this “material effect” behind football: the often unseen contribution of material science to the way the sport is played, experienced and connected around the world.

The athletes enabled by materials

Modern football has become faster, more precise and more connected. Players sprint more, press harder, change direction faster and perform under intense physical and mental pressure. Behind this evolution are better training methods and data analytics, but also materials that help make high performance more reliable.

The football itself is a good example. Modern balls use advanced materials, carefully engineered surfaces and precise construction methods to support consistent weight, shape, rebound and flight behavior, even under demanding weather conditions. Compared with traditional leather balls, today’s footballs are designed for greater reliability and more predictable performance.

Footwear has also changed fundamentally. Modern football boots combine lightweight uppers, flexible structures and high-performance sole plates to support grip, acceleration, agility and ball control. The contact between player, pitch and ball has become a highly engineered interface.

Sportswear plays its part as well. Lightweight, breathable and durable textiles can help manage moisture and comfort during high-intensity performance. Covestro’s INSQIN^® waterborne polyurethane technology enables high-performance textile coatings that can provide softness, water resistance and long-lasting performance while supporting more sustainable manufacturing approaches.

Materials beyond the pitch

The material effect extends beyond players and equipment. Stadiums, training facilities and broadcast infrastructure also depend on advanced materials.

Lightweight and durable polycarbonate solutions have been used in large-scale roofing applications. They can help create weather-resistant structures that protect spectators while reducing weight and maintenance requirements.

At the same time, football is becoming increasingly digital. From connected match technologies and live analytics to broadcast systems, streaming platforms and fan experiences, every match depends on the reliable flow of data. Advanced polymer materials help protect cables, connectors and electronic components and support the infrastructure that brings the game to fans around the world.

As sport becomes more connected, the infrastructure behind it becomes more demanding. Data centers, communication networks and electronic systems require materials that can support reliability, protection and performance at scale.

Innovation is a team sport

The evolution of football shows how performance is rarely the result of a single factor. It comes from the interaction of talent, preparation, technology and the right materials.

The same applies in business. As customer challenges become more complex and markets move faster, innovation increasingly depends on collaboration across disciplines, industries and value chains.

“Innovation today needs to be fast, focused and collaborative,” said Monique Buch, Chief Commercial Officer at Covestro. “Co-creation with customers works much like collaboration in a football team: different strengths come together around one shared goal, focusing their preparation to secure the win, and trust and speed making the difference.”

From the pitch to the stadium and from equipment to digital infrastructure, football shows how advanced materials can help shape performance where it matters most.

“Taiwan is a critical hub for the global electronics and electrical industry and an innovation base for forward looking applications such as AI robotics,” said Alec Yang, Head of Sales and Market Development TPU Taiwan of Covestro. “With our TPU APAC R&D center and manufacturing site in Changhua, we can directly support local customers for material development and scale up for critical applications including consumer electronics and artificial intelligence. This enables an efficient transition from R&D and application validation to localized mass production, addressing the diverse demand for high-performance and sustainable materials across the regional value chain.” 
 

Enabling performance leaps for AI-Powered Robots in the Real World

In the field of service robotics, AI is accelerating the transition from single‑purpose function to diverse and complex real-world scenarios, which raises the bar for material performance. Overall robotic performance depends not only on algorithms and mechanical design, but also on the stable performance of key components under high‑frequency operation. With excellent abrasion resistance, flexibility and mechanical strength, TPU has become one of the key enabler for motion functions and critical movements in robotics applications.

Driven by AI, household cleaning robots are gaining enhanced capabilities in recognizing complex environments and types of dirt, while market now expects cleaning performance across more scenarios. The material performance of core components — such as seals, rollers, side brushes and wheels — directly affect suction efficiency, cleaning results, obstacle climbing capability and traction. To ensure stable cleaning across complex floor conditions, materials must maintain controlled deformation and durability under prolonged dynamic loads. Covestro's Desmopan® IT series TPUs delivers stable performance under high-frequency operation and supports low-noise operation across a variety of floor surfaces. In high-humidity or wet environments, such as pool and garden cleaning robots, this material also offers excellent hydrolysis resistance and antimicrobial properties, helping extend equipment lifetime and enhance reliability.

Biomimetic designs in embodied intelligence place higher requirements for mobility, protection and human-machine interaction. In critical structural and exterior components, TPU can deliver skin-like softness and conformability while maintaining durability and chemical resistance under repeated stress and everyday use. For example, foams made with Desmopan® FLY can be used in foot structures to provide excellent cushioning and rebound. Desmopan® AIR series utilizes a parallel-layered extrusion process to create multi layer cushioning structures, supporting customized biomimetic designs as well as prototyping and performance validation during development. In tactile sensing and safe interaction, TPU serves as a foundational material for electronic skin solutions. flexible TPU films bring tactile sensing to dexterous hands and electronic skin while improving flexibility in the hands and fascial structures. In systems involving high frequency dynamic motion, TPU is also used for cable jacketing in robotic arms and operating equipment. Its outstanding flexibility and mechanical strength under repeated bending, ensuring long term stability of signal transmission and power delivery, it also meets flame retardant requirements, making it suitable for industrial robots and for electronics and electrical applications with stringent safety and environmental standards.

Combining rubber-like elasticity with the strength of engineering plastics, TPU also offers excellent processability and recyclability. Suitable for multiple molding methods, including injection molding and extrusion, supporting robotics products from prototyping to large-scale production.

Delivering High Performance and Sustainability for AI Laptops and Smart Devices

As intelligence continues to evolve in end devices, material innovation is playing an increasingly vital role in enabling performance upgrades and sustainable design in consumer electronics.

As AI functions deeply integrated into everyday work, creative and mobile use scenarios, laptops face higher requirements in terms of high speed computing, lightweight design, thermal management and environmental sustainability. Components such as foot pads and thermal management components, which support heat dissipation and anti-slip functions in laptops, can be overmolded with TPUs of different hardness, helping optimize overall device weight while improving recyclability. Covestro’s Desmopan® XHR series TPU offers excellent heat and wear resistance, maintains outstanding mechanical performance under sustained high temperature conditions, making it particularly suitable for devices with demanding thermal management requirements, such as servers and gaming laptops. In response to the growing sustainability trend, Desmopan® CQ series TPUs uses bio-based feedstocks and the mass balance approach can achieving a share of sustainable content of over 80%. While delivering comparable performance to conventional fossil-based materials, helping brands reduce carbon footprint across the entire product life cycle.

In smart connected devices such as speakers and gateways, Desmopan® IT series TPU can be used in exterior panels and base plates, combining pleasant haptics, vibration damping and long term stability, while offering broad design freedom for brands. In flexible wearable devices that come into direct contact with skin, such as smart bands, watch straps and earphones, Desmopan® IT series TPU delivers a soft, skin-friendly touch along with excellent abrasion resistance and antimicrobial properties, ensuring lasting comfort during prolonged wear, while maintaining high standards of hygiene and meeting the demanding requirements of health monitoring and fitness tracking applications.

“Material innovation in the AI era is not only about boosting performance, but also about enabling more efficient product development and more reliable mass production,” said Kevin Ho, Head of Sales and Market Development TPU APAC of Covestro. “Focused on ongoing innovation in high-performance TPU materials and related technologies, we continue to expand what’s possible in cutting-edge applications, supporting customers in visionary project development and accelerating the transition from validation to scale. Our TPU Application Development Center, opened this May in Guangzhou, works in synergy with the Taiwan R&D Center to strengthen technical support across Asia Pacific as a global manufacturing hub. Combined with our regional production and supply chain network, Covestro will keep driving performance leaps and sustainable progress in electronics and electrical applications for the AI era.”

The global AI infrastructure market is experiencing rapid expansion across multiple sectors. AI server shipments to the United States from Taiwan-based manufacturers nearly doubled year-on-year in 2025[1], driven by demand from hyperscale data center operators, while data center power densities in AI-optimized facilities now exceed 100kW per rack. The robotics sector is transitioning from research and development to commercial deployment, with embodied intelligence applications—including logistics robots, humanoid platforms, and intelligent automation systems—entering mass production. Taiwan's semiconductor industry, which accounts for over 60% of global advanced semiconductor manufacturing capacity[2], is projected to reach NT$7.1 trillion in output in 2026, representing 24.4% year-over-year growth[3] driven by High Bandwidth Memory (HBM), GPU production, and advanced packaging technologies, according to the Market Intelligence & Consulting Institute (MIC). As production scales across these sectors, manufacturers require material solutions that meet technical specifications while providing supply reliability and local technical support.

“Technology is moving faster than ever, and AI is opening up entirely new possibilities across industries,” said Lily Wang, President of Engineering Plastics at Covestro. “At Covestro, we deliver high-performance, sustainable material solutions that help our customers move faster, backed by a stable global supply network that scales with them. ‘The Material Effect’ is about pushing industry boundaries while advancing the circular economy, and turning good ideas into lasting impact.”

Unleashing the AI Computing Revolution

Covestro is presenting material solutions for AI data centers, computing hardware and semi-conductor manufacturing during COMPUTEX 2026. 

“We bring together expertise from across our business areas to create integrated solutions that help customers accelerate innovation,” said Thomas Derichs, Global Head of Industrial Marketing Electronics & Electrical at Covestro. “Through close collaboration, we are enabling the leap from prototype to production, from concept to commercial.” 

For AI data centers and supercomputing servers, Covestro's polycarbonate solutions provide flame retardancy, thermal management, and lightweight properties for power distribution, energy management, cooling systems, IT hardware, and chips. These solutions support reliable operation in high-density computing environments and mission-critical applications. 

Further upstream in the supply chain, advanced semiconductor wafer storage and transport demand strict cleanliness, visibility and dimensional precision. Covestro’s ultra-clean transparent solutions for FOSB (Front Opening Shipping Box) provide low outgassing and high transparency, while anti-static solutions protect wafers from electrostatic discharge damage and particle adhesion. These polycarbonate solutions contribute dimensional stability and heat resistance to help reduce contamination risks, improve chip yield and support the safe handling throughout wafer storage and transportation process. 

AI notebooks, gaming devices and peripherals are driving demand for materials that support both performance and distinctive design. Covestro offers carbon fiber-reinforced, high glass fiber-reinforced, and transparent flame-retardant polycarbonates, enabling lightweight, high-strength designs, premium quality and bold visual effects. 

Shaping the Future of Embodied Intelligence

As one of COMPUTEX 2026's core focus areas, embodied intelligence represents a defining frontier where The Material Effect comes to life. Drawing on expertise across its businesses, Covestro provides a broad material portfolio for embodied intelligence. 

Covestro’s polycarbonate solutions enhance lightweight structural components with outstanding impact resistance, and provide high infrared transmittance for accurate environmental sensing in sensor housings. Rigid polycarbonate films support human-machine interaction through ambient lighting and touch functionality, while flexible TPU films bring tactile sensing to dexterous hands and electronic skin. Flexible TPU elevates hands and fascia with soft, elastic, skin-like conformability for fingertip covers and outer panels, delivering durable, chemical-resistant performance under repeated stress. 

Covestro is also working with value-chain partners to accelerate material solutions for real-world robotics applications. Through its collaboration with Hikrobot, Covestro supports high-performance material solutions for smart logistics and machine vision applications, helping advance the commercialization of logistics robots. Together with Carthane, Covestro is exploring structural components, Cast PU elastomers for feet and joints protection systems for robots. 

For commercial robot vacuum cleaner, Covestro worked with Roborock to develop more sustainable material solutions for next-generation intelligent products. The company’s sustainable TPU solutions enable lighter, easily processable functional parts—such as brushes and wheel coverings, support both performance and design freedom. 

Crafting Tomorrow's Connected World

As AI drives intelligence into every connected device, advanced connectivity is raising the requirements for smart devices and the infrastructure behind them. Beyond performance, applications increasingly call for refined design, sustainability and engaging user experiences. 

Covestro’s material solutions support these evolving needs across connected applications. For satellite broadband and communication equipment, Covestro’s polycarbonate solutions combine high signal transmittance with long-term outdoor stability, supporting reliable connectivity in demanding environments. In next-generation Wi-Fi routers. Makrolon® TC polycarbonate solutions help dissipate heat while maintaining signal transparency, and optimizing total cost ownership, addressing both thermal management and cost-efficiency needs of more compact and powerful connected devices. 

In smart home and IoT devices, flame-retardant design-forward materials bring connected homes to life. For AR/VR and wearable devices, optical-grade materials deliver comfort, durability and visual immersion for long-term everyday use. Covestro’s HMI (human to machine interface) solutions further enhance smart living experiences by integrating interfaces, sensing functions and lighting effects into compact device designs, creating more intuitive and seamless smart surfaces. 

Combining Sustainability and Aesthetics

In the era of sustainable consumption, low-carbon products with refined aesthetics have become a key differentiator for businesses. 

Covestro addresses this from the ground up, building a diversified recycling ecosystem to secure supply chains, matching PCR (post-consumer recycled) waste streams to specific technical requirements that fulfill industry standards. To strengthen material traceability, supply stability, and quality consistency, Covestro has diversified PCR feedstock with various sources such as water bottles, ELV (end-of-life) headlamps, and wafer boxes broadly used in the semiconductor industry as wafer carriers, to empower a comprehensive PCR portfolio and GLOCAL supply. This diversified approach has contributed to the high-performance Makrolon® R series, delivering glass-fiber reinforced grades with strong impact strength as a distinctive and reliable solution for the market. 

Covestro also offers bio-circular attributed material options, helping customers further reduce carbon footprint without compromising performance. This is demonstrated in products like the Bayblend® RE in BLUETTI’s Elite 100 V2 power station, which contains 25 percent bio-circular attributed content, reducing its carbon footprint by over a fifth compared with the conventional model. Additionally, Covestro offers a portfolio of NIA-PFAS (Non-Intentionally Added Per- and Polyfluoroalkyl Substances) materials with good flame-retardant performance and robust mechanical properties, aligning with the EU’s proposed PFAS restrictions and the latest EPEAT guidelines. 

In the global AI era, CMF trends reflect both functional imperatives and emotional design language. Translucent and gradient finishes communicate technological transparency and innovation, while nature-inspired textures and earth-tone palettes bridge the digital-physical divide, making advanced AI systems feel approachable rather than alien. Covestro works closely with design institutions and enterprises to find the right balance between aesthetics, functionalities and environmental footprint of sustainable materials. Covestro's CMF capabilities ensure that material innovation keeps pace with design ambition. By integrating color consistency, surface innovation, and circular material science, Covestro empowers customers to bring both sustainability and aesthetics to life, translating circular material choices into distinctive, reliable and market-ready products that meet the evolving demands of the AI era. 

Join Covestro at the “Grab the development trend of material effects in AI era” seminar in Taipei on June 4, 2026, to discover how high-performance materials can support the next wave of AI-driven innovation. Register at: http://www.caemolding.org/activity-20260604/

[1] taiwannews

[2]MIC AISP

[3] 【MIC FORUM】2026臺灣半導體產值創新高 達7.1兆新台幣　AI應用朝代理與實體深化 成為半導體中長期成長動能 | 資策會產業情報研究所（MIC）

The new compressor operates on the principle of a heat pump: Water vapor is generated during the production processes for TDI, a component of flexible foam. Covestro requires steam for many production processes, but the steam produced during TDI manufacturing is not hot enough. Therefore, some of it is released into the environment as waste heat. The compressor raises the steam to a higher temperature and pressure level, making it suitable for use in production processes.

“Energy efficiency is a key lever for transforming our production towards climate neutrality and a circular economy. The principle is: the less energy we need, the better,” says Thorsten Dreier, CTO of Covestro. “That’s why we’re using every opportunity to make our production even more energy-efficient with modern, innovative process technologies.” From 2005 to 2022, Covestro already reduced its energy consumption by around 40 percent. The next goal: By 2030, the company aims to consume 20 percent less energy per ton of product produced than in 2020.

This project is part of an energy efficiency strategy with which Covestro is driving its transformation to climate-neutral production. As part of the master plan, the company is continuously searching for further potential energy efficiency measures. “With these projects, we are not only reducing our CO₂ emissions, but also saving on energy costs,” says Andreas Doerfer, Global Energy Excellence Manager. “To achieve our energy efficiency target, we must utilize all available options for using the waste heat generated in our processes to manufacture our products.”

Following the installation of an energy-efficient reactor at the TDI plant last year, the new compressor for the Dormagen site is the next major project to future-proof the location: “This investment clearly demonstrates Covestro’s long-term belief in the Dormagen site and its commitment to investing here,” says Philip Bahke, Head of Operations in Dormagen and North Rhine-Westphalia.

Construction is scheduled to begin at the end of this year, with the compressor expected to go into operation in mid-2027.

“The circular economy must prove its value in markets. The global launch of this new suitcase shows recycled materials can meet expectations for both performance and design,” said Lily Wang, President of Engineering Plastics at Covestro. “We are pleased to deepen our long-standing collaboration with NINETYGO and to help more Chinese brands differentiate globally through sustainability.”

“NINETYGO is committed to advancing sustainable travel worldwide. Today’s consumers expect not only quality and design, but also environmental responsibility,” said Alisa Shang, CEO of Runmi Technology, which owns NINETYGO. “Together with Covestro, we are bringing to market a new generation of PCR-based luggage that combines performance with sustainability, while strengthening our global competitiveness.” 

Combining sustainability and durability

The suitcase shell is made from Makrolon® R90 with up to 90 percent recycled content, sourced from end-of-life water barrels. Since 2020, Covestro has collaborated with partners to recycle around 1 million 19-liter polycarbonate barrels annually, converting them into high-quality PCR material for use in consumer goods, electronics and home appliances.

For example, a 20-inch suitcase from the Coffee Journey Series reduces the shell carbon footprint by over 67 percent[1] compared to the previous version, thanks to a higher content of circular materials.

In terms of performance, the recycled material maintains strong impact resistance at room temperature and in extreme conditions down to -20°C. It also offers excellent color versatility, with this new Coffee Journey Series available in three colors: Flat White, Americano and Latte, reflecting the material’s natural aesthetic.

Enabling global reach through sustainability

NINETYGO first partnered with Covestro in 2021 to launch a limited-edition suitcase using PCR polycarbonate. The global debut of the Coffee Journey Series marks a deepening collaboration between the two companies and underscores the accelerating trend of sustainable material adoption in consumer products.

Environmental requirements in international markets have tightened in recent years. Regulations such as the EU’s Ecodesign for Sustainable Products Regulation (ESPR) and restrictions on per- and polyfluoroalkyl substances (PFAS) are raising the bar for market entry. The PCR polycarbonate used in the latest NINETYGO series contains non intentionally added PFAS (NIA-PFAS) and aligns with proposed EU PFAS restrictions. With strict raw material control and standardized production, it delivers performance comparable to virgin materials and is certified by third parties for PCR content.

Visit Covestro at CHINAPLAS 2026, Hall 7.2, Booth C38, National Exhibition and Convention Center (Shanghai), to discover how the Material Effect is shaping the future.

[1] Based on NINETYGO internal calculations.

Under the agreements, signed during CHINAPLAS 2026, Covestro and Hikrobot will co-develop solutions for parcel sorting, factory automation and related applications, with Hikrobot prioritizing Covestro’s material solutions and receiving full R&D support. The collaboration with Carthane will focus on commercializing advanced materials for critical robot components such as feet.

“Covestro is evolving from a material supplier to a strategic enabler across the robotics value chain,” said Lily Wang, President of Engineering Plastics at Covestro. “At a critical stage of industrial-scale deployment, we are deepening collaboration with industry pioneers to advance next-generation materials, accelerate scalable production, and embed sustainability from the start — supporting the robotics industry on a greener path.”

Partnering with Hikrobot for smart logistics

Hikrobot is a provider of machine vision, mobile robots and articulated robot products and solutions, focusing on industrial IoT, smart logistics and intelligent manufacturing. Covestro and Hikrobot are joining forces to develop products and system solutions for smart logistics and intelligent manufacturing.

“We are delighted to enter this strategic partnership with Covestro in high-performance materials and intelligent logistics. Covestro’s comprehensive material technology support will help Hikrobot enhance its product innovation capabilities and market competitiveness. We look forward to achieving more breakthroughs together at both the technology and product levels,” said Xie Mingqiang, Vice President and Head of Supply Chain at Hikrobot.

As the logistics industry accelerates its intelligent transformation, robots face increasing demands for precision, stability and service life. Under the MoU, the two companies will co-develop applications in express delivery, e-commerce and factory automation. Hikrobot will prioritize Covestro’s material solutions, while Covestro will provide comprehensive R&D and testing support.

Covestro addresses key challenges in smart logistics with advanced materials. For example, Bayblend® polycarbonate enables lightweight, impact-resistant housings and structural components, while Makrolon® polycarbonate offers high infrared transmittance for precise sensing and movement.

Partnering with Carthane: from automotive to robotics

Building on their established collaboration in elastomer materials for the automotive sector, Covestro and Carthane will expand into robotics, focusing on applications such as robot feet.

“Covestro is a long-trusted strategic partner of ours. Our successful collaboration in the automotive sector provides a solid foundation for this expansion into robotics. Covestro’s strengths in material innovation complement Carthane’s capabilities in value chain management and systems integration, and together we will drive the commercial adoption of advanced materials in the robotics sector,” said Hou Zhenkun, Director and General Manager of Carthane.

Robot feet and joints require high performance in shock absorption, noise reduction, impact resistance and durability. Covestro’s Vulkollan® elastomer, with its outstanding dynamic load-bearing capacity and fatigue resistance, as well as excellent wear and impact resistance, effectively protects critical robotic components, significantly extends the service life of robot feet, and enhances overall operational stability and reliability.

Visit Covestro at CHINAPLAS 2026, Hall 7.2, Booth C38, National Exhibition and Convention Center (Shanghai), to discover how the Material Effect is shaping the future.

“Technological innovation is advancing at an unprecedented pace, reshaping industries worldwide. The rapid rise of AI in particular is creating a wave of new applications,” said Lily Wang, President of Engineering Plastics at Covestro. “In response, Covestro continues to develop sustainable, high-performance solutions for customers, leveraging the ‘Material Effect’ to redefine industry boundaries and drive innovation in next-generation mobility, electrical and electronics, and healthcare, while advancing our commitment to a circular economy.”

Advancing Intelligence Frontiers

Advances in AI and intelligent technologies are reshaping industry boundaries, giving rise to sectors such as low-altitude aviation, embodied intelligence and smart energy. These emerging industries require lightweight design, long-term reliability and high system safety to scale commercially, creating new demands for advanced materials.  

At CHINAPLAS 2026, Covestro will showcase the AirCab flying car developed by Chinese partner GOVY, illustrating the material possibilities for electric vertical takeoff and landing (eVTOL) aircraft. From lightweight polycarbonate windshields and integrated roof sensor modules to polyurethane encapsulation foams for battery safety and sustainable coating solutions for lightweight aircraft bodies, Covestro’s portfolio addresses key material challenges of eVTOL aircraft, helping them fly farther and more safely. Covestro materials also support AI navigation systems and lightweight structures for drones, helping advance the next generation of logistics.

Covestro will also present its complete solutions for humanoid robots. Polycarbonate enhances robot structural components with outstanding impact resistance for safer operation in challenging environments; in chip and electronic control housings and support structures, it enables efficient heat dissipation and integration with precision components; in battery enclosures, its flame-retardant properties maintain even temperature distribution for long-term stable operation under high heat; and in sensor housings, its high infrared transmittance supports accurate environmental sensing. In addition, rigid polycarbonate films can support human–machine interaction through ambient lighting effects and touch functionality, while flexible TPU films enable tactile sensing in dexterous hands and electronic skin.

In the smart energy sector, the increasing integration of energy storage, charging infrastructure and grid systems places higher demands on long-term outdoor reliability. Covestro’s polycarbonate solutions for equipment enclosures deliver durable performance in demanding environments, supporting applications ranging from energy storage and EV charging stations to residential clean-energy systems and portable power solutions.

Elevating Smart Living

As AI reshapes industries and daily life, it is raising the bar for everyday devices and the infrastructure behind them. Data centers and supercomputers need materials that meet strict standards for flame retardancy, thermal management and structural strength under high-density computing loads. Covestro’s bio-circular attributed Makrolon® RE solutions can help ensure reliable operation while reducing carbon emissions by around 80 percent compared to conventional alternatives.[1] For consumer electronics such as gaming devices and AI-powered laptops, Covestro offers glass fiber-reinforced or carbon fiber-reinforced engineering plastics with high stiffness, high translucency and flame retardancy, enhancing product performance, design and user experience.

Connectivity is also evolving rapidly, with satellite broadband bringing reliable, high-speed internet directly to homes, even in remote areas. Covestro’s engineering plastics ensure high signal transmittance, impact resistance and mechanical durability for terminals, enabling stable operation around the clock in demanding environments.

Empowering Connected & Trusted Healthcare

As wearable devices, remote care and AI-assisted diagnostics become more widespread, healthcare is moving closer to the home. Covestro has developed medical-grade material solutions across wearable monitoring, molecular diagnostics and precision drug delivery, helping enable a more connected and trusted healthcare ecosystem.

In diagnostics, Covestro showcases its material solutions through the Maestro point-of-care demonstrator. Built around Makrolon® Dx polycarbonate, the device leverages its optical clarity and low fluorescence to improve signal accuracy, enabling more precise molecular diagnostics in connected devices. In drug delivery, Covestro’s all-polycarbonate injection pen demonstrator uses low-friction, glass fiber-reinforced medical-grade polycarbonates to ensure smooth delivery, structural strength and dimensional stability. Adhesive-free assembly also enables easier disassembly and recycling. For medical wearables designed for extended wear, Covestro’s TPU films offer skin-friendly softness and excellent elasticity, providing a barely-there fit.

Visit Covestro at CHINAPLAS 2026, Hall 7.2, Booth C38, National Exhibition and Convention Center (Shanghai), to discover how the Material Effect is shaping the future.

[1] The CO2 footprint reduction is based on a cradle-to-gate life cycle assessment comparing Makrolon® RE to conventional polycarbonate and considers biogenic carbon uptake. The certified bio-circular share is attributed through mass balance methodology according to ISCC PLUS.

"The contract with Fraunhofer UMSICHT is a decisive step towards industrializing our smart pyrolysis technology," said Dr. Markus Dugal, Head of Process Technology of Covestro. "This partnership combines our chemical and technology expertise with Fraunhofer's process engineering capabilities and assets to scale a technology that is able to prove chemical recyclability of end-of-life Polyurethane materials and that could fundamentally change how we source raw materials for MDI production. By recovering high-value molecules from waste streams, we're turning the circular economy from vision into reality while significantly reducing the carbon footprint of our products."

Under the agreement, Fraunhofer UMSICHT will draw on its pyrolysis research expertise and existing chemical recycling infrastructure to implement and scale up Covestro's proprietary smart pyrolysis process. The pilot plant has an annual capacity to recycle 2kt of end-of-life foam per year. The resulting amount of aniline could be used to produce insulation for roughly 200,000 refrigerators² . The new plant is scheduled to begin operations in mid-2028 and will process rigid PUR/PIR foam waste primarily from end-of-life insulation PU materials. The technology specifically targets rigid foam because it is notoriously difficult to recycle due to its crosslinked molecular structure.

Moving towards industrial implementation

"This project represents the culmination of several years of intensive joint research," explains Prof. Dr.-Ing. Manfred Renner, Head of Institute Fraunhofer UMSICHT. “It’s perfectly in line with Fraunhofer’s mission to bridge the gap between research and application: we are not just demonstrating technical feasibility but actively moving towards industrial implementation.” Dr. Alexander Hofmann, Head of Thermochemical Conversion Technologies at Fraunhofer UMSICHT adds: "The project is underpinned by our own research and technology developments in chemical recycling and downstream processing. The pilot plant will allow us to optimize process parameters at scale and provide sufficient material for further processing tests and market development."

The smart pyrolysis process yields aniline with approximately 99 percent purity, suitable for producing recycled MDI that meets the same quality standards as conventional MDI.

Rigid foam market in need of closed-loop solutions

This development is particularly important as the MDI market for rigid foam is projected to grow from 1400 kt in 2025 to 1900kt in 2035 in Europe alone, driven by increasing demand for energy-efficient insulation in buildings and refrigeration. EU regulations and market requirements, for example, increasingly request scalable end-of-life solutions for PUR/PIR rigid foam, posing a significant challenge for the industry. The chemical recycling technology developed by Covestro and Fraunhofer UMSICHT offers a viable path forward by breaking molecular bonds to recover valuable raw materials that would otherwise be lost.

The technological development builds on extensive research within CIRCULAR FOAM, an EU-funded flagship project coordinated by Covestro with Fraunhofer UMSICHT and 23 other partners across Europe. After successful laboratory and mini-plant scale demonstrations, the smart pyrolysis pilot plant represents the critical next step toward commercial implementation.

For more info visit the Covestro Solutions Center

_{¹ The carbon footprint was calculated for the recycled aniline produced by the smart pyrolysis process without using any credits for avoided incineration. With this value the CO₂ emission for MDI was calculated for the standard production process of Covestro.
² Assuming ~8kg of PUR insulation per refrigerator}

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

For BLUETTI, the main challenge lies in ensuring that the device's housing lasts as long as its internal components. With more than 4,000 charging cycles – about 10 years of use – BLUETTI's LiFePO4 battery requires a housing that withstands aging, brittleness, and wear, even under extreme temperatures and UV exposure. Safety is equally crucial, as the material must tolerate heat during operation without fire risk. Beyond these high material requirements, BLUETTI is strongly interested in reducing the CO₂ footprint of its products, which is why the material must also meet this requirement.

Covestro's Bayblend^® polycarbonate meets both requirements: It offers high impact resistance even at low temperatures and complies with UL 94 V-0 flame retardant standards for safe operation. The Bayblend^® RE grade used in the Elite 100 V2 power station is also manufactured with renewable ingredients attributed through mass balance accounting from biological waste and residues, while meeting high performance requirements. The material is part of Covestro's CQ (Circular Intelligence) product portfolio, which marks products related to at least 25 percent alternative raw materials.

"This collaboration with BLUETTI demonstrates how innovative materials can accelerate the transition to more sustainable solutions for the rapidly growing portable power market," said Lily Wang, Global President of Engineering Plastics at Covestro. "Our engineering plastics designed for the circular economy not only deliver the technical performance required for demanding outdoor applications, but also help our customers reduce their environmental footprint while advancing the circular economy."

Allen Huang, Vice President of BLUETTI, added: "Our partnership with Covestro is based on a shared vision for a greener planet. By using their advanced bio-circular attributed materials, we enhance the durability and safety of our products while actively reducing our environmental impact. This collaboration enables us to offer reliable, stylish, and sustainable energy solutions that empower our users to live better lives."

Beyond technical performance, Bayblend^® enables refined surface textures and diverse color options through Covestro's advanced CMF (Color, Material and Finish) capabilities. This design flexibility allows BLUETTI to meet evolving consumer preferences for more expressive, aesthetically appealing products without compromising performance standards.

The Elite 100 V2 will be launched on January 7 afternoon at BLUETTI’s CES booth #9837 in the North Hall of the Las Vegas Convention Center and be available globally.

¹ The CO₂ footprint reduction is based on a certified life cycle assessment of the housing component comparing Bayblend^® RE to conventional polycarbonate. The bio-circular content is tracked and correspondingly attributed through certified mass balance methodology.

The collaboration seeks to develop a circular economy model for medical devices by proving both technical feasibility and economic viability while navigating the complex regulatory landscape of medical waste management. In cooperation with additional partners in the United Kingdom – including Allmed’s distribution partner Kimal, a leading regional hospital trust and a specialized recycler – Allmed and Covestro are now preparing for their first recycling trials.

“The circular economy in healthcare is still emerging – but it holds tremendous potential. With this feasibility study, we want to demonstrate that even complex applications like artificial kidney filters can be circular and become a valuable source of high-quality polycarbonate recyclate instead of being incinerated or sent to landfill,” says Lily Wang, Global Head of Engineering Plastics at Covestro.

Allmed is equally committed to ambitious sustainability goals: “Blood purification devices are essential for life-saving treatments but also require significant resources. Our ambition is to show that high medical performance and ecological responsibility can go hand in hand,” explains Ahmed Sorour, Chief Executive Officer at Allmed.

Matt Press, Chief Executive Officer of Kimal Group added: "We are very proud that Allmed had chosen Kimal and the UK market to be at the forefront of this fantastic and groundbreaking initiative".

About Allmed:
Allmed is a leading innovator and supplier of groundbreaking blood purification devices. It encompasses the widest portfolio of such devices globally, from neonatal care up to the largest blood filters on the market. It is headquartered in the UK, with key technology centers in Germany, and exports its devices and technologies to over 40 countries worldwide. Allmed is committed to showcasing to the world that even life-saving medical devices can enter and exit the supply chain sustainably.

Find more information at Allmed – Delivering world class Dialysis Treatment
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Michael Huang, Head of Sales & Market Development Taiwan of Covestro Engineering Plastics, stated: "From smart home devices and robots to servers and 5G base stations, all require innovative housing materials with thermal conductivity and impact resistance to ensure stable device operation—only then can AI truly deliver stable performance. Meanwhile, international regulations continue advancing toward sustainability, signifying the increasingly prominent demand for low-carbon, circular recyclable materials. Addressing these two major transformations, Covestro offers numerous trend-setting polycarbonate solutions that meet the protective capabilities and performance requirements of products across different application scenarios." 

Alec Yang, Head of Sales and Market Development Taiwan of Covestro TPU, further elaborated: "Beyond enhanced thermal management performance, there is also an increasing focus from consumers on long-term comfort and durability for frequently used wearable smart products. Covestro's TPU comprehensively addresses these challenges, providing solutions that combine sustainability with exceptional product performance." 

Covestro will introduce the distinctive features of its polycarbonate and TPU solutions based on AI-related application requirements during the forum. Regarding housing applications, Covestro emphasizes that its thermally conductive polycarbonate solutions achieve lightweight design with heat management capabilities and stable wireless connectivity, replacing traditional metal components for outdoor and indoor smart devices, routers, and more. As AI permeates every aspect of consumers' daily lives, it requires the stable and safe operation of outdoor telecommunication infrastructure and charging facilities. Covestro's low-temperature impact-resistant polycarbonate materials help 5G base stations and satellite receivers maintain signal stability in extreme environments (-40℃ to 85℃) and high-salt conditions, and can also be applied to charging stations and power conversion systems. 

Beyond performance innovation, Covestro continues to lead in advancing the circular economy and sustainability, offering low-carbon polycarbonate solutions that incorporate alternative raw materials or post-consumer recycled content. Additionally, closely following the industrial transformation driven by evolving environmental regulations, some polycarbonate products also feature trend-setting solutions available for selection (such as NIA-PFAS¹ ). 

Furthermore, in peripheral materials, Covestro's TPU demonstrates excellent thermal wear resistance for heated components in high-performance computing equipment (such as foot pads). TPU can also be integrated with PC/ABS materials, delivering superior tactile experiences for home devices while providing noise reduction and anti-yellowing properties. The flame-retardant TPU series is particularly suitable for applications across industries where fire safety is critical, including automotive charging cables and consumer electronics power cables. 

Through this forum presentation, Covestro will demonstrate its technical expertise and sustainability commitment in AI-driven material innovation, providing important material solution references for Taiwan's plastics industry transformation and upgrading in the AI era. 

¹  PFAS (Per- and Polyfluoroalkyl Substances) are a class of fluorinated chemicals widely used in industrial and consumer products due to their heat resistance, chemical resistance, and water-repellent properties. As products without PFAS components are more environmentally friendly and better for human health, NIA-PFAS (Non-Intentionally Added PFAS) alternatives have become a global development trend across various industries.

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

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.

While global population growth is slowing slightly, the number of people over 65 is expected to double by 2050. Older people want to remain mobile, independent, and socially integrated. At the same time, already overburdened healthcare systems must become more efficient and accessible. High-performance plastics enable medical innovations and intelligent environments that help seniors maintain independence and participate actively in society. Materials developed by Covestro support for example self-tracking with wearables and smartwatches, as well as telemedicine and remote monitoring.

Solutions for an Aging Global Population and Growing Middle Classes

Alongside the increasing number of seniors, the global middle class is also growing steadily. Despite regional differences, this population segment is expanding fastest – especially in Asia – and is expected to grow by more than one billion people this decade. With rising prosperity, the demand for high-quality products as well as expectations around comfort and sustainability are also increasing. Plastics featuring Covestro materials enable durable, smart, and resource-efficient goods that improve quality of life while reducing environmental impact.

A common factor across much of humanity is increasing connectivity. Over the next decade, we’re likely to live in a hyperconnected world enabling up to one million 5G-enabled digital devices per square kilometer. However, the digital revolution also brings growing levels of electronic waste and sharply rising electricity demand, particularly from data centers. Powerful, highly energy-efficient, and environmentally friendly devices and networks are therefore essential. Robust, recyclable plastics with versatile functions are indispensable in this regard.

Covestro is closely observing global trends such as socio-demographic change, urbanization, and developments in mobility, nutrition, and healthcare. The company provides forward-thinking plastics and their precursors, acting as a driver of progress across key industries.

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.

"With our automated laboratory, we can work together with our customers on the future of coatings and adhesives. Because it operates almost completely autonomously and learns from our existing knowledge and data lake as well as newly generated data, it makes the process of optimizing and developing formulations many times more efficient and precise. This allows us to optimize existing formulations faster or even develop completely new formulations for and together with our customers. We can say: We are reaching a new level of modern research," says Thomas Büsgen, head of the laboratory.

Testing Formulations with Covestro Binders and Crosslinkers 

Specifically, the new laboratory will test formulations with Covestro binders and crosslinkers for coatings and adhesives. Their clever selection ensures properties such as hardness, adhesion, opacity, gloss, or durability. Such formulations typically consist of seven to 15 components, whose combination determines the properties of the final product. The resulting high number of possible combinations means that standard formulations are usually used. The new laboratory now enables more extensive test series, also thanks to the computer-aided design of test series and the use of automation.

"Our new automated laboratory gives us more possibilities for testing formulations. It relieves our specialized laboratories of their standard tasks and can analyze samples more systematically. This allows us to focus our expertise and experience even more on customer-specific topics or try approaches we couldn't have implemented otherwise," says Martin Merkens, Head of Sales & Market Development EMLA in Covestro's Coatings and Adhesives business entity. “This will particularly help us in the area of circular economy: Alternative raw materials, for example bio-based or recycled materials, can be tested faster and evaluated for their properties in the final product.”

Facility to Run Tens of Thousands of Tests Annually 

The new facility can operate 24 hours a day, 7 days a week. The goal is to run tens of thousands of tests annually. This sets a new standard in terms of number, variety, precision, and testing speed. Another advantage: The automated laboratory generates a large amount of structured data. The knowledge about formulation possibilities and influencing factors thus will grow rapidly. The collected data, combined with measurement data from existing studies, is evaluated using special machine learning algorithms to further improve formulations. Artificial intelligence is also used to predict new experiments based on property goals and simultaneously verify them in the automated laboratory – creating a self-learning system.

In addition to formulating water- and solvent-based 1K and 2K systems, the automated laboratory also performs numerous material tests on the raw materials themselves, their formulations, and applied films. Application can even take place in different climates in the lab to simulate product use under application conditions. The progressing laboratory digitalization across Covestro also enables easy forwarding of generated samples to more specialized testing laboratories. This makes it possible to supplement the datasets with market-specific test results and identify relevant dependencies more quickly.

Covestro at European Coatings Show 2025 in Nuremberg 

At the European Coatings Show from March 25-27 in Nuremberg, experts from application development and segments such as automotive, printing & packaging, or construction & architecture will be present to discuss new, joint approaches made possible by the laboratory with customers. Visit the company's booth in Hall 4A, Stand 438. There you can learn more about the laboratory and other innovative material solutions and technical developments for the coatings and adhesives industry.

Follow further updates on this topic here. 

“While the decision to shut down the PO11-unit is difficult, we must ensure all assets within our portfolio are a long-term strategic fit,” said Aaron Ledet, executive vice-president I&D and Supply Chain at LYB. “We are prioritizing our core assets which play a key role in our technology differentiation and circularity strategy or provide attractive returns over the cost of capital. We take our obligations towards our employees, European employee reps, councils, and unions seriously. We have engaged with them in line with these obligations and will continue to do so. We would like to thank them for the constructive dialogue. We are also in communication with customers, suppliers and other parties across the value chain and will continue to do business as usual. There is no change to our working relationship, and we continue to focus on providing an exceptional customer and supplier experience.”

"As part of our Sustainable Future corporate strategy, we’re continuously working to optimally position Covestro to be a reliable partner for our customers and to operate competitively in a challenging market environment," said Hermann-Josef Dörholt, Head of the Performance Materials Business Entity at Covestro. "Due to global overcapacities, persistently weak demand, and high costs in Europe, we have jointly decided with LYB to close the PO11 plant. We will support LYB in implementing this change as socially responsibly as possible. At the same time, we remain committed to the European market and will continue to supply customers with our renowned polyether polyols portfolio.”

The Maasvlakte site, a joint venture between LYB and Covestro, has been operational in the Rotterdam region since 2003. Between now and the end of 2026, LYB will carry out a process to safely shutdown and prepare the demolition of the asset.

In 2024, LYB announced a strategic review of European assets of its Olefins & Polyolefins (O&P) and Intermediates & Derivatives (I&D) business units. LYB has taken the next step in evaluating the option to seek alternative ownership for the O&P sites in the strategic assessment. At this time no decisions have been made and various outcomes remain possible.

Special focus is placed on technologies that increase productivity while promoting circular economy. These include an automated laboratory for formulation development, material screening, and polymer analytics; an innovative Direct Coating process for the automotive industry, and a TÜV-certified, cloud-based solution for product-specific lifecycle analyses (LCA).

"Our customers' and partners' challenges are becoming increasingly complex. Be it accelerated development cycles, ever-higher product requirements, or circularity and recyclability. We offer innovative solutions that not only convince technologically but also make an important contribution to greater sustainability," explains Martin Merkens, Head of Sales & Market Development EMLA in Covestro's Coatings and Adhesives business entity. "At ECS 2025, we demonstrate how we make customers and partners successful and can accompany them every step of the way. We look forward to personal meetings and discussions!"

Automated Laboratory Revolutionizes Application Development

At ECS, the company will announce an automated laboratory for optimizing formulations with Covestro's binders and crosslinkers for coatings and adhesives. With this, Covestro sets new standards in the productivity of its application development. The new facility can operate 24 hours a day, 7 days a week. The goal is to conduct tens of thousands of tests annually. This sets a new benchmark in terms of quantity, variety, precision, and testing speed. Another advantage: The automated laboratory generates a large amount of structured data. The knowledge about formulation possibilities and influencing factors thus will grow rapidly. The collected data, combined with measurement data from existing trials, is evaluated using special machine learning algorithms to further improve formulations. Application development experts and specialists from segments such as automotive, printing & packaging, or construction & architecture will be present at ECS to discuss new collaborative approaches now made possible by the laboratory.

Digitalized Lifecycle Analyses for Greater Transparency

As a pioneer in the digital transformation of the chemical industry, Covestro announced in January the use of a new cloud-based solution for product-specific lifecycle analyses (LCA). The TÜV Rheinland-certified software solution not only enables significantly faster and more precise calculation of a products' environmental footprint but also identifies concrete approaches to reducing the CO₂ footprint, thus supporting Covestro's customers in their sustainable transformation.

Direct Coating: Solutions for the Automotive Industry

With the innovative Direct Coating technology, Covestro presents a pioneering solution for the automotive industry that fundamentally simplifies the coating process while making it more sustainable. This technology enables direct coating of plastic components in the injection molding machine without pretreatment or separate painting and drying. At ECS, Covestro will display products that were manufactured using this process.

Focus on Sustainability

Covestro aims to fully align itself with the circular economy. This includes using alternative raw materials, transitioning to green energy, and developing recycling technologies and recyclable products. To make sustainable products more easily identifiable, the company has introduced the "CQ" label, which stands for "Circular Intelligence." Products labeled this way contain at least 25% alternative raw materials. Several examples used in coatings and adhesives will be exhibited at ECS. For example, food packaging coated with fully recyclable, partially bio-based resins, or water-based polyurethane dispersions for textile printing.

Additional information on Covestro’s presence at the ECS can be found at: https://solutions.covestro.com/en/digital-event-space/ecs or on the LinkedIn-channel of the business entity Coatings and Adhesives.

In response to the growing demand for sustainable solutions in currency printing, Covestro is introducing Autentium^®, an innovative polymeric printing substrate. Designed exclusively for currency printing applications like banknotes, Autentium^® combines cutting-edge anti-counterfeiting technology with a recyclable mono-material design.

"The launch of Autentium^® represents a significant breakthrough in currency printing, offering an innovative, recyclable polymeric substrate that excels in printability, durability and is more sustainable," says Daniel Hentschel, Global Segment Manager for ID & Security Printing at Covestro.

Key Features of Autentium^® include:

• Exceptional printability: It supports secure printing techniques such as intaglio and offset, enabling embossed structures and therefore tactile security features that differ from traditional paper and existing polymer substrates.
• No coatings or primers needed: Its secondary properties as a hot-melt adhesive contribute to superior ink adhesion without requiring additional primers or coatings, streamlining the printing process and improving durability.
• Water & Stain Resistance: The polymer absorbs only minimal moisture, which contributes to a low static charge, while at the same time being resistant to contamination.
• Advanced laser engraveability: It allows precise micro-engravings, providing advanced anti-counterfeiting measures and enhancing currency security.
   

As a single-polymer solution, Autentium^® is recyclable, addressing the demand for sustainable materials in banknote production. Its high tear propagation resistance and excellent ink adhesion contribute to extend the lifespan of printed currency and can help reducing the environmental impact and conserving resources.

Furthermore, its durable composition can translate into long-term costs savings by minimizing replacements, making it an ideal choice for governments and the public sector that prioritize security and environmental responsibility.

Meet Covestro at Intergraf Currency + Identity 2025 

Covestro will showcase Autentium^® and other advanced polymeric solutions at the Intergraf Currency + Identity 2025 trade show. Join us from March 5-7, 2025, at the Allianz MiCo, Milano, Italy. Visit us at booth 16 to discover how Autentium^® can redefine your security printing requirements and drive innovation in currency production.

The competition, which will be contested by university undergraduates from the UK and Ireland, is asking students to design a product, made primarily from plastics, which will promote or monitor either physical or mental health.

Chairman of DIP, Martin Sixsmith, said that with increased focus on the self-care agenda, the 2025 theme offers an exciting opportunity for creating a product which can seamlessly integrate into daily life and which can help all age groups.

“This is a subject which resonates with many people and it therefore offers a huge amount of scope for students to showcase their creative talents for the benefit of others,“ he said. “We are very much looking forward to seeing their end product!“

Students will need to submit their entries by March 14, when DIP’s panel of industry judges will whittle the submissions down to a final six. Final judging will take place in London on May 9, with the award ceremony on June 20.

Design Innovation in Plastics is the longest running plastics competition of its kind in Europe, having been established in 1985. It is supported by the Institute of Materials, Minerals and Mining, the Worshipful Company of Horners and sponsored by leading design and plastics organisations, including Covestro.

Notes to editors 

1. Established in 1985, Design Innovation in Plastics is the longest running student plastics design award in Europe. For more information visit www.designinnovationplastics.org.

2. The Institute of Materials, Minerals and Mining (IOM3) is a major UK engineering institution and is the professional body for the advancement of materials, minerals and mining to governments, industry, academia, the public and the professions. For more information visit www.iom3.org.

3. The Worshipful Company of Horners is one of the oldest livery companies in the City of London, formed to regulate the horn-working trade. In 1943 it adopted its modern equivalent, the plastics industry. For more information visit www.horners.org.uk.

4. Headline industry sponsor – Covestro

Hanno Bruemmer, Head of Supply Chain and Logistics EMLA at Covestro, stated: “The entire value chain must be involved to achieve our joint goal of climate neutrality by 2050. Reliable, efficient and sustainable logistics for our ever more sustainable products are integral to this effort. We collaborate with our customers and transport companies to optimize the supply chain. This includes improving load capacity, selecting the best transport modes and routes, and introducing using sustainable and future-oriented energy sources like green electricity or HVO to replace fossil fuels.”

As part of the collaboration, DB Cargo BTT provides Covestro with an end-to-end transport solution that combines several sustainable approaches: First, the chemicals are transported in tank containers from the production sites of Covestro in Germany to a nearby railway terminal using bio-fuel (HVO 100)-driven trucks. The tank containers are then transported to a distribution center in Poland via rail, keeping trucks off the road and saving respective emissions. From there, bio-fuel (HVO 100)-driven trucks are again deployed to distribute the chemicals to end customers in Poland to ensure on-time delivery. This particular bio-fuel is one of the most sustainable alternatives to fossil diesel. Altogether, the combination of these modes of transport saves at least 70% of CO₂ emissions compared to conventional road transport methods.

Torsten Lüders, Managing Director of DB Cargo BTT GmbH, points out: “At DB Cargo BTT, we also rely on working with external partners across all modes of transport in order to arrange traction or first and last mile services as efficiently as possible for our customers. For Covestro, we have recently transported essential chemical products to Poland and we’re now happy to combine our rail expertise with bio-fuel-driven trucks for the first and last mile. This collaboration exemplifies our commitment to enabling more sustainable supply chains and supporting the transformation of the chemical industry. Projects like these demonstrate how we, as part of the DB Cargo group, offer our customers a significant degree of added value and are an essential part of European supply chains.”

The collaboration is designed to be flexibly scaled in the future to accommodate growing business needs. It also sends an important signal to customers of Covestro, such as the Polish Selena Group, a global manufacturer of construction chemicals and materials, who benefit from the delivery of MDI with a lower carbon footprint, as it helps to reduce their Scope 3 emissions.

Bernd Hennig, Head of Trading Cluster MDI at Covestro remarked: “Together with Selena Group, we are committed to advancing sustainable solutions across the entire value chain, offering our valued customers not only more sustainable materials but also sustainable transportation solutions.” Michal Specjalski, Member of the Management Board of Product and Innovation at Selena Group added: “Today, sustainable business no longer means having to compromise between efficiency and quality. In Selena Group we are constantly increasing our commitment to the development of sustainable construction. We carefully follow trends and changes in the world around us. We are constantly working on minimizing our environmental impact and rational resource management. That’s why we are delighted to have Covestro and DB Cargo BTT at our side as strong partners who share our commitment to reducing emissions and achieving climate neutrality targets in Europe and worldwide.”

Selena Group and Covestro are already collaborating in multiple ways to advance the circular economy. For instance, they are developing polyurethane (PU) foams for improved thermal insulation in buildings which are based on MDI of the Desmodur^® CQ product range. It is ISCC Plus-certified, using plant-based raw materials through mass balancing. As a result, these products have a lower carbon footprint compared to those derived from fossil raw materials—and now, thanks to the transport solution, they will also be delivered to Selena in a more sustainable way.

¹ _{The reduction in CO₂ emissions is based on a comparison between the use of HVO100 renewable diesel and conventional fossil diesel}

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.

For the highly competitive construction sector, the product sold by Selena offers clear advantages: It can be used with various types of blocks (ceramic, silicate, ACC) with high accuracy and allows for a higher yield compared to traditional cement mortars. The product also improves construction efficiency by curing twice as fast as traditional cement mortars. Additionally, it can be used in a wide range of operating temperatures from -5 degrees Celsius to +30 degrees Celsius, which helps reduce temperature-induced work stoppages.

“Materials play a decisive role for an ever more climate neutral and circular economy”, said Bernd Hennig, Head of Trading Cluster MDI EMEA at Covestro. “If materials providers early in the value chain join forces for climate neutrality, the impact on end products will be significant. In this spirit, we are therefore very happy to deepen our collaboration with our like-minded partner Selena to help the construction sector bring down emissions and meet its climate neutrality targets in Europe and worldwide.”

Buildings are responsible for over one third of greenhouse gas emissions in the EU alone. As about 75% of the buildings in Europe do not meet energy efficiency requirements, the building sector faces a wave of renovations over the coming years. In fact, the EU has just recently updated the Energy Performance of Buildings Directive (EPBD). It states that by 2050, all buildings in the EU should be net-zero emission buildings².

More sustainable adhesive instead of cement

“With existing and upcoming climate neutrality regulations for the construction sector, we expect a steeply rising demand for sustainable building materials”, said Miroslaw Truchan, Senior Category Development Manager, Selena Group. “With a great partner like Covestro, we jointly drive innovation in the construction materials industry. We both believe that innovative products can play a vital role in achieving climate neutrality targets and put us ahead of the curve.”

The Tytan Professional^® Adhesive for Bricklaying uses Desmodur^® CQ MB of Covestro, a bio-based MDI (methylene diphenyl diisocyanate), of which the plant-based feedstock is mathematically attributed to the final product via the mass balance approach certified by the ISCC Plus standard.

Tytan Professional^® Adhesive for Bricklaying is the third product launched from the collaboration between Selena and Covestro. The partnership was deepened in 2023, aimed at collaborating to craft a more sustainable range of polyurethane (PU) foams for enhancing thermal insulation of buildings. Bio-attributed methylene diphenyl diisocyanate (MDI) of the Desmodur^® CQ MB-series of Covestro is already being used in an enhanced version of Selena’s Ultra Fast 70 one-component foam, primarily applied in the installation of windows and doors. Also, this product is ISSC Plus certified to include plant-based feedstocks through mass balancing and allows for an up to 45% reduced carbon footprint compared to fossil-based products.

_{¹Comparison of 1 can of Tytan Adhesive for Bricklaying (750ml) with the data for generic cement mortar for 1,5 x 25 kg bags.
²https://www.consilium.europa.eu/de/infographics/fit-for-55-making-buildings-in-the-eu-greener/#:~:text=Mit%20der%20%C3%9Cberarbeitung%20der%20Richtlinie,in%20der%20EU%20Nullemissionsgeb%C3%A4ude%20sein}

Covestro’s CERTEVO^® revolutionizes security printing with several key features: It supports excellent printability via intaglio and offset processes, enabling embossing structures—surpassing traditional paper and enhancing security elements. Its hotmelt nature eliminates the need for coatings and primers, ensuring superior ink adhesion that simplifies printing and boosts durability. Additionally, advanced laser engravability allows precise micro-engravings, making counterfeiting efforts more challenging.

As a single-polymer composition, CERTEVO^® is recyclable, meeting the demand for sustainable security printing materials. Its high tear resistance and ink adhesion extend the lifecycle of printed items while conserving resources. CERTEVO® thereby addresses environmental concerns and meets evolving sustainability requirements in document production.

Furthermore, its durable composition lowers long-term costs by minimizing replacements, making it an ideal choice for governments and the public sector that prioritize security and environmental responsibility. 

Meet Covestro at TRUSTECH 2024

Covestro’s team will be present at the TRUSTECH trade show, held at the Paris Expo Porte de Versailles - Pavilion 5.2, from December 3-5, 2024. We invite industry professionals and stakeholders to discuss with us at meeting room 8 and discover how CERTEVO^® and other advanced polymer materials can transform their security printing needs.

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.

“Healthcare manufacturers are increasingly adopting sustainable materials to reduce their carbon footprint, and it is our goal to help customers reach their sustainability ambitions,” said Sam Shodi, Head of Specialty Films North America, Covestro.

According to Shodi, the Makrofol^® polycarbonate film provides the transparency, toughness and sterilization suitability needed for many medical applications an example of which is medical implant packaging. “This advancement meets the demands of our healthcare customers, where sustainable materials are crucial for reducing environmental impact while maintaining high quality and safety standards,” he concluded.

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. Covestro has major sites across all regions that are ISCC PLUS certified. Among them are world-scale sites like Baytown, Texas; Leverkusen, Dormagen and Krefeld-Uerdingen, Germany; Shanghai, China; Map Ta Phut, Thailand; and Antwerp, Belgium.

Customers can discover more about Covestro’s mass balance films and other premium material solutions, including how they support sustainability goals and drive advancements in medical devices, at the upcoming MEDICA 2024 and COMPAMED 2024 trade fairs, November 11-14 in Düsseldorf, Germany.

“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.

Beyond Leather’s approach captures the value of apple waste – of which around 4 million tons is produced every year – by upcycling it into a high-performance and more sustainable alternative to conventional leather made with animal skin. With a high content of short fibers and polymers, apple waste (including cores, seeds, and stems) can be activated to give a strength and suppleness to the final material, recreating the functional and aesthetic properties that make leather so desirable. To produce LEAP^®, the apple-waste blend is applied to a TENCEL^TM textile backing and finished with the protective coating containing INSQIN^® PU.

Inspirational leather-look products; aspirational performance

For brand customers and end consumers looking for leather alternatives, the launch of LEAP^® stands as a testament to the power of innovation and collaboration.

“With around 25% of an apple discarded after pressing, we wanted to capture this waste’s value in premium applications. We believe that looking into waste streams and using upcycling is crucial to reduce emissions. It is our mission to show how much value there is in waste and, ultimately, make waste beautiful,” says Mikael Eydt, Co-Founder & CEO, Beyond Leather Materials.

“Covestro is delighted to have contributed to the development of this leather alternative made with apple waste, which has significant potential to improve textile sustainability in a wide range of industries,” says Dr. Torsten Pohl, Head of Global Textile Coatings Covestro. “Our low-VOC, low-emission, waterborne, and partly-bio-based INSQIN^® coating technology is the perfect fit for LEAP^®, enabling the premium durability, flexibility and perceptual quality needed in today’s market while offering a more sustainable solution for partners like Beyond Leather. We look forward to continuing our collaboration in applications spanning everything from small goods typically made of leather such as wallets, purses, and key cases, to automotive interiors.”

“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.

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.

Although less associated with the chemical industry or the circular economy, design plays a key role in enabling circularity through various means. It offers a huge opportunity for providers of sustainable and high-performance materials like Covestro to bring in their expertise.

“The design phase determines a large part of a product’s environmental impact: From the choice of materials to repairability, from a long and useful product life to recyclability. We therefore can’t understate the topic of design when we want to become fully circular,” explains Dr. Christopher Stillings, Head of Color & Design at the Business Entity Engineering Plastics within Covestro. “As materials experts early in the value chain, we at Covestro sit in the sweet spot to consult our customers and partners on how to use circular design principles when conceiving a product. We want to systematically collaborate with designers to make use of that.“

Gaining momentum

And while product design is not new, a shift is indeed happening - also due to regulators placing increasing emphasis on the topic. For example, the EU is tightening its requirements for environmentally friendly product designs, and approved new rules to make products sold in the EU more reusable, repairable, upgradeable and recyclable. There is also a proposal for a DIN “Method to achieve circular design of products” on its way. In the USA, the Department of Energy is pursuing its “Strategy for Plastics Innovation”, which also includes the factor of “Recyclability by design”. Other regulatory bodies are discussing similar initiatives.

To use that momentum, Covestro offers solutions in several main areas:

• Dematerialization, e.g. by digitalizing sampling processes. Covestro recently announced its new IMAGIO^® CQ digital sampling tool for that purpose.
• Design for longevity. This is bread and butter for a high-performance materials manufacturer that provides materials e.g. for products for cars, buildings or the cold chain that have a lifetime of several decades.
• Modular design makes it easier to disassemble products and recycle the parts.
• The use of circular raw materials with a low emission footprint make products made of such material more circular to begin with.

The push for circular design is getting stronger and Covestro is addressing the topic on various fronts. In fact, it has been addressing the topic for decades already and can build on that expertise. The K67, a car entirely made of plastics made for the K-fair back in 1967, is just one example.

Under this partnership, one of Covestro’s key roles is to provide more sustainable plastic solutions along with their carbon footprint data. Alibaba Cloud’s Energy Expert, an AI-driven sustainability platform, plays a crucial role in realizing the whole life cycle emission accounting from recycled materials to final consumer products leveraging digital technology such as blockchain. It also provides an end-to-end solution for industrial companies to measure and optimize their carbon footprint across their production lifecycle.

“As a materials manufacturer with a high focus on sustainable material innovation, Covestro is committed to driving circularity and climate neutrality. Our collaboration with Alibaba Cloud marks a significant milestone in our journey towards a circular and climate-neutral future,” says Lily Wang, Global Head of the Engineering Plastics Business Entity, at Covestro. “With our joint solutions, we are supporting our customers to improve their supply chain transparency while building trust among environmentally conscious consumers, thereby driving industries towards a greener future.”

“We are proud to partner with Covestro in pioneering sustainable solutions that drive positive environmental impact,” says William Xiong, Vice President of Alibaba Cloud Intelligence. “By leveraging our advanced cloud infrastructure and expertise in sustainability technology, we are enabling value chain partners to trace materials with enhanced transparency and efficiency as well as to optimize their carbon footprint to achieve their sustainability target. This partnership exemplifies the transformative power of technology in creating a more sustainable future.”

The joint solutions offered by the two parties have already been implemented in the consumer goods sector. For example, Covestro collaborated with China’s leading beverage maker Nongfu Spring to recycle its 19-litre water barrels into post-consumer recycled polycarbonate. The material was then used by KACO, a niche stationary brand in China, to produce gel pens. Through Alibaba Cloud Energy Expert’s carbon emission accounting and digital tools, consumers can scan a QR code on the packaging of the pens to trace the origin of the material, see a detailed breakdown of the carbon footprint at each stage in the production chain and the number of carbon emission slashed compared to the virgin materials.

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.

The aim of the partners is to recycle the sorted polyurethane foams as efficiently as possible by combining mechanical and chemical technologies after careful sorting by foam type in the mattress cutting plants.

Collaborations leveraging own expertises with like-minded partners are key: In addition to Ecomaison and Covestro, the French dismantling company Secondly and Federal Eco Foam, a Belgian specialist in the mechanical recycling of flexible foams, are involved as partners in the project, which is planned to run for a maximum of 24 months. The project is called Foam Recycling Ecosystem Evolution (FREE) and coordinated by Covestro and half-funded by Ecomaison.

For the FREE consortium, the motivation lies in the added value of the material that can be recovered from the used foams and the opportunity to enter a more sustainable circular economy. The partners want to explore all possibilities in a future-oriented foam recycling ecosystem and are convinced that chemical and mechanical recycling will complement each other in a meaningful way. As dismantler and sorting actor, Secondly is interested in empowering its sorting processes to be able to supply to recyclers a specified quality of foam.

At the same time, the project will provide a good picture of how the foam recycling market in the coming years may look like. The partners truly believe that chemical and mechanical recycling can be complementary given different specifications of inlet materials being sorted already at dismantlers. To provide added value to the PU foam material, the consortium will investigate all possibilities in a future oriented eco-system of foam recycling.

The research and development project includes the foam sorting at the dismantling step, as well as a comparative feasibility study for two recycling processes for the sorted foams covering economic and ecologic value co-creation.

A few years ago, Covestro and its partners developed a chemical recycling process that is the only one of its kind capable of ultimately recovering both main raw materials of flexible PU foams in high purity. The company also operates a pilot plant at the Leverkusen site for this purpose. Together with the waste management industry, the company wants to drive the process forward to industrial use.

To make its vision of a fully circular economy a reality, Covestro is making the development of innovative recycling technologies a priority and calls the evolution of recycling Evocycle^® CQ. The chemolysis of PU mattress foam is the first initiative of Covestro of its kind and is called Evocycle^® CQ Mattress.

The award is presented by the "German Design Council." Candidates submit projects that have been launched on the market no longer than five years ago, but they can also be nominated by the council. The evaluation is carried out by an independent, interdisciplinary expert jury. The award ceremony took place on May 14 in front of around 300 invited guests at the Futurium in Berlin.

"We are very pleased that the German Design Council has honored us with this award," said Joan Miquel García Martínez, Senior Project Manager Arfinio^® at Covestro. "Arfinio^® is a real breakthrough for design, surfaces, and sustainability. This award shows the relevance of combining design, manufacturing technology, and materials for the development of new products and confirms that we are on the right track."

The Arfinio^® technology, which Covestro has developed together with its partner Arcesso, a manufacturer of custom polyurethane parts, combines liquid high-performance polymers and unique minerals with the RIM process (reaction injection molding). This combination enables seamless shapes and surfaces – and was long considered impossible. The resulting products are durable, repairable, and lightweight, can be produced quickly, and allow for free designs. The material also contributes to sustainability as it can be produced with partially bio-based raw materials, can be mechanically recycled at the end of its life cycle, and reused for the production of new products.

During the joint developments with Covestro, it turned out that a plastic from the Makrolon^® RE series meets the aforementioned requirements very well. This is an ISCC PLUS-certified polycarbonate with raw materials from biological waste and residues allocated via the mass balance approach.

Compared to a fossil-based standard type, the selected polycarbonate during its production (cradle to gate¹ ) has a CO₂ footprint that is reduced by around 80 percent with a share of more than 85 percent allocated renewable raw materials. Makrolon^® RE polycarbonate is part of Covestro's CQ family, a label used by the company to identify products with a physical or attributed content of at least 25 percent alternative raw materials.

In addition to the selection of more sustainable materials, the development of the new device focused on energy efficiency during use. Deutsche Telekom specifies the carbon dioxide equivalents saved for 1,000 MagentaTV One-devices in energy-saving mode at around 15,500 kilograms per year. Accordingly, the telecommunications company has marked the device with the #GreenMagenta label to underline its positive contribution to climate protection and the responsible use of resources.

"Reducing the CO₂ emissions of plastic parts is an important issue for us in order to achieve our ambitious climate targets," says Dr. Steffen Wasmus, Group Partnering & Devices at Deutsche Telekom. "Makrolon^® RE makes a valuable contribution to this. The collaboration with the global Covestro team was extremely helpful, as they significantly supported us in the selection and application of suitable materials." Deutsche Telekom aims to achieve net-zero emissions in scope categories 1 to 3 by 2040 across the entire value chain, from production to the use phase of their products.

"Deutsche Telekom is an important partner for us. We jointly want to achieve climate goals and drive the transition to renewable raw materials. Makrolon^® RE makes it possible to use biowaste as a renewable carbon source for the telecommunications value chain without compromising on performance and design," adds Dr. Niklas Meine, Industrial Marketing Electrical & Electronics in the Europe, Middle East, Africa (EMEA) region at Covestro.

Deutsche Telekom's design team was particularly interested in high-quality processing of the devices, as well as intuitive handling of the device and user-friendly plug-and-play installation.

The mass-balanced polycarbonates from the Covestro RE portfolio offer the important advantage of achieving virgin product quality and covering a wide range of applications, as they have the same good product and processing properties as their purely fossil-based counterparts. In the case of MagentaTV One, Deutsche Telekom is for the first time using a Makrolon^® RE which displays high transmittance in the near-infrared (NIR) radiation for the TV box and remote.

¹ _{This takes into account a partial product life cycle from raw material extraction (cradle) to the factory gate (of Covestro), also known as cradle-to-gate assessment. The methodology is based on the ISO 14040 and 14044 standards and has been critically tested by the TÜV Rheinland on plausibility. The calculation takes into account biogenic carbon uptake.}

"A paradigm shift and intensive cooperation along the value chain are needed for the transition to a circular economy to succeed. The chemical and waste management industries in particular must continue to grow together in the future in order to create synergies and develop solutions together," says CEO Dr. Markus Steilemann. "With innovative recycling technologies and now also as an authorized waste dealer, Covestro is well equipped for this. We can now actively shape partnerships for waste management and a recyclate portfolio in the EU ourselves."

"IFAT brings together many established players in waste management. In addition to making new contacts, we also want to position chemical recycling, which is often still viewed skeptically, as an integral part of a modern circular economy. By participating in IFAT, Covestro is demonstrating to many stakeholders the contributions our company wants to make to circular integration," says Tara Nitz, Manager Global Circular Economy and responsible for IFAT cooperation at Covestro.

Broad portfolio of recycling technologies

In addition to various exhibits showing current examples of recycling solutions and partnerships, Covestro uses the world's leading trade fair for the waste management industry to explain mechanical and chemical recycling technologies in order to create transparency and strengthen confidence in the efficiency of such developments. The company has many years of experience in the mechanical recycling of polycarbonates and thermoplastic polyurethanes (TPU) and only last year significantly expanded its capacities for the processing of mechanically recycled products in China and Thailand.

For Covestro, chemical processes include chemolysis as a method for recovering raw materials under the influence of chemicals, smart pyrolysis at elevated temperatures and enzymatic recycling, in which microorganisms break down the chemical bonds. What they have in common is that the polymer molecules are converted back into the original raw materials, from which new products of the same quality as new goods can be created. The processes will be clearly explained at the Covestro stand on the "Recycling Wheel".

At IFAT, Covestro will also show how circular solutions in its product portfolio are becoming even more recognizable for customers. With the “CQ” concept, Covestro emphasizes the alternative raw material base for its products if it is at least 25 percent. “CQ” stands for Circular Intelligence. With the new recycling technologies, the CQ portfolio is now growing even further. This includes the reuse of polyurethane mattress foam components – the first chemical recycling initiative marketed by Covestro under the name Evocycle^® CQ.