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Baypreg® STM for lightweight battery pack covers and underbody protection for EVs
Enhance your battery pack for electric vehicles (EV) with Baypreg® STM! Our innovative polyurethane (PU) Spray-Transfer-Molding (STM) technology provides the efficient production of versatile battery composites within a short cycle time, enabling battery pack manufacturers to substantially reduce weight and increase fire protection.
Story · May 23, 2025
The process delivers significant manufacturing advantages: short cycle time, high automation potential, efficient material usage, and the integration of flanges for mounting on the battery casing. Additional functional material layers and thin steel sheets can be integrated into the composite structure during the compression step, if required.
The final components outperform traditional solutions with up to 60% weight reduction compared to steel, while providing high mechanical properties and excellent flame retardancy to increase fire protection in case of a thermal event. Additional benefits include electrical insulation, a part smooth surface, gas impermeability and corrosion resistance - making Baypreg® STM ideal for modern EV applications.
EV battery underbody protection lightweight PU composite solution
For vehicle underbody protection, Baypreg® STM offers a unique sandwich design combining our proven Spray-Transfer-Molding technology with a rigid polyurethane foam core. The efficient process allows manufacturers to create strong, lightweight panels featuring acoustic properties, durability and impact resistance, protecting the battery pack against stone chipping and ground impact loads. The resulting components provide comprehensive vehicle protection with integrated functionality for modern mobility solutions.
Key benefits
Protection:
Comprehensive shielding against impacts, stones, and environmental factors
Efficient Production:
Short cycle times and high automation enable efficient, cost-effective manufacturing
Design freedom:
Integration of mounting flanges and functional layers in a single production step
Weight Savings:
Up to 60% lighter than steel solutions, improving EV range and efficiency
High Strength:
Superior mechanical properties while maintaining significant weight reduction
Safety First:
Excellent Flame retardancy to shield & protect against fire
