This article reports on how the latest advances in plastic materials are benefiting the most demanding applications in the automotive field. An investigation of the implications of forthcoming legislation on plastic materials in cars, especially in their fuel systems, was presented in a paper at Autotech 97; this study was conducted by the Shell Research and Technology Centre at Amsterdam. Its authors speculated that, in future, operating temperatures in this area would increase to 60-90 degrees C, with peaks up to 120 degrees C, and that the materials used in fuel systems would have to withstand very aggressive fuel additive packages. Further improvements to system integration will be needed, to minimise potential leakage points. The authors also presented the case for the superior fuel permeating behaviour of the polymer Carilon. Both Delphi and Dow Automation have developed glass-filled injection-moulded plastic composite structural cross-car beams, which do not use steel and function as both a structural retainer and a primary HVAC air distribution system. The beams' better performance was validated after analytic modelling and testing. Dow Automotive has collaborated with Chrysler and Venture Industries to develop a head impact system for upper trim that met the latest US Federal regulations.

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