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Innovation Planets Parts

JEC World


Lightweight Thermoplastic Convertible Roof Beam

Röchling Automotive SE
The solution replaces magnesium with advanced thermoplastics and provides proof of concept for use in structural automotive applications. It uses a hybrid molding technology combining thermoforming and injection molding, enabling complex geometries for seamless integration into the vehicle while reducing component weight by 700g and cutting part count by 50%.

Why and Whom

Mercedes-Benz AG approached Röchling to develop a part that would reduce cost, weight, and component count, while setting new standards in lightweight and interior design for convertibles.
Röchling successfully met these challenges through iterative development- and design processes, combined with leading production methods and collaboration with Envalior, who co-led the CAE simulation.

Partners

Mercedes-Benz AG | Bond Laminates by Envalior

Key Benefits

Traditionally, the front end of a convertible's fabric roof system includes a visible plastic trim, contrasting with the materials of the windshield frame and headliner. Removing this plastic trim creates a seamless transition between the headliner and windshield frame, offering a unique selling proposition for the Mercedes-Benz CLE Cabrio.

Awards

Award Finalist - Automotive & Road Transportation - Parts
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