Automotive

Exterior Solutions
Optimised performance and surface
aesthetics
Borealis and Borouge
partners for long-term success

Building on Borealis unique Borstar technology and
experience in polyolefins of more than 50 years, Borealis
and Borouge provide innovative, value creating plastics
solutions for the infrastructure pipe systems and power
and communication cables automotive and advanced
packaging industries. In addition, Borealis offers a
wide range of base chemicals from melamine and plant
nutrients to phenol and acetone.
Borealis is a leading provider of innovative solutions in the
fields of polyolefins, base chemicals and fertilizers. With
headquarters in Vienna, Austria, the company currently
has around 6,500 employees and operates in over 120
countries. Borealis generated EUR 7.7 billion in sales
revenue and a net profit of EUR 988 million in 2015. The
International Petroleum Investment Company (IPIC) of Abu
Dhabi owns 64% of the company, with the remaining 36%
belonging to OMV, an international, integrated oil and gas

Production
Fibremod production
Customer Service Centre/
Sales Office
Head Office
Innovation Centres
company based in Vienna. Borealis provides services and
products to customers around the world in collaboration
with Borouge, a joint venture with the Abu Dhabi National
Oil Company (ADNOC).
Building on its proprietary Borstar and Borlink
technologies and more than 50 years of experience in
polyolefins, Borealis and Borouge support key industries
with a wide range of applications in the areas of energy,
automotive, pipes, consumer products, healthcare, and
advanced packaging.
The Borouge 3 plant expansion in 2015 made Borouge
the worlds largest integrated polyolefins complex. The
additional 2.5 million tonnes of polyolefin capacity
increased the total Borouge annual capacity to 4.5 million
tonnes, attaining a combined Borealis and Borouge annual
capacity of 8 million tonnes.
Borealis offers a wide range of base chemicals, including
melamine, phenol, acetone, ethylene, propylene, butadiene
and pygas, servicing a wide range of industries. Borealis
also creates real value for the agricultural industry, selling
approximately 5 million tonnes of fertilizers. Technical
nitrogen and melamine products complement the portfolio
with applications ranging from mono-nitrogen oxide (NOx)
abatement to glues and laminates in the wood working
industry.
Borealis and Borouge aim to proactively benefit society
by taking on real societal challenges and offering real
solutions. Both companies are committed to the principles
of Responsible Care, an initiative to improve safety
performance within the chemical industry, and work to solve
the worlds water and sanitation challenges through product
innovation and their Water for the World programme.
Contents

06 Engineered to be more than the sum of its parts

07 Committed to advancing performance

08 Essential surface aesthetics

09 Continuing to build on success

11 Materials portfolio for exterior applications

Engineered to be more than the sum of its parts

Appearance, performance, integration and sustainability its lines fluid and seamless, and its surfaces smooth and
combine to make tomorrows cars more than just the dynamic. Achieving this requires a unique set of material
sum of their parts. From first sight a vehicle must have properties balanced for peak performance in meeting the
presence, its colour must be consistent and unblemished, needs of each specific application.

Density
Stiffness
Impact
Physical
Properties

Surface
Thermal expansion
Quality
Flowability
Cycle time

Paint adhesion
Class-A surface
Processability Scratch resistance

Stabilisation
Sustainability
Colour harmony
Weatherability

Ultimately, reliability in each particular respect is confirmed
by the reality of day-to-day and long-term performance.
For tough, practical and aesthetically important exterior
applications our PP and TPO compounds provide the
strength and surface characteristics to replace metals and
engineering plastic materials. Our products do so without
any compromises in mechanical performance to give
corrosion-free reliability throughout a vehicles lifespan.
Moreover, they enable significant weight savings and
greater vehicle fuel economy.

6
Committed to advancing performance
At Borealis and Borouge we are dedicated to developing
material solutions which meet both existing and future
needs of the industries we serve. This process is guided by
creative innovation working with partners to identify needs
before they become challenges and developing solutions
that add value along the supply and production chain.
To support these goals Borealis operates three world class
Innovation Centres.
Our innovation teams are engaged in the development
of new materials or material improvements, as well as
customer technical services ranging from part design
and prototype simulation to the production and testing
of batch samples and assistance with the initiation of
series production. They are also tasked with the ongoing
improvement of Borealis own methodologies and processes.
Simulation
Compound Material Science
Molecular Modelling
A nm
Borealis
Production R&D Compound
Modelling and Simulation Value Chain of Borealis
A maximum performance of components can only be
achieved if component design, material and processing are
optimally balanced. Borealis has the necessary capabilities
and tools: we have developed sophisticated application
testing methods and standards, which, combined with
modelling and simulation methodologies, can offer
comprehensive support to customers in developing and
implementing applications.
This can minimize the need for the customer to undertake
expensive prototyping, reduce testing costs and lower
quality issues in the project start up phase.
Application Engineering
Conversion Engineering
Process Modelling
m mm dm m
Labs Marketing & Sales Conversion Application
7
Essential surface aesthetics
Exterior appearance provides consumers with vehicle
first-contact and the impression that will inform and
condition their judgements and purchasing decisions.
Therefore, the presentation of a Class-A surface finish is
essential for all exterior applications whether unpainted,
painted or moulded-in colour.
Unpainted solutions
Flow marks, often referred to as tiger stripes, are
frequently occurring surface defects in injection moulding
of thermoplastic materials. They result in defective
surfaces that have a negative effect on the visual
quality of unpainted parts and represent a production
and cost challenge for Tiers and OEMs. To address this
problem Borealis has introduced a next-generation of
PP compounds based on the latest Borstar technology
polymers, delivering a premium surface appearance across
a very broad processing window.
As we strive to enhance our portfolio of customer solutions,
Borealis developed a novel test method to simulate and
quantify the occurrence of tiger stripes. Borealis has
subsequently developed and invested in proprietary
equipment for tiger stripe testing at its Innovation
Headquarters in Linz.
Flow mark testing equipment at Innovation Headquarters, Linz, Austria.
Primerless painting
Borealis is also supporting a growing industry trend
towards primerless paint systems for exterior plastic
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applications. Primerless painting addresses the need
to reduce cycle time and system costs by moving from
a 3 step process to a 2 step process in painting. These
systems are economically attractive, however, less
forgiving in terms of process fluctuations. A feature of this
trend has been increasingly stringent criteria in respect of
paint adhesion performance. Hence, the polymer and paint
system has to be well tailored and adjusted to each other
and production processes need to be reliable and robust.
To help OEMs overcome this challenge and achieve greater
economy Borealis has undertaken a major R&D initiative
to develop primerless two-layer paintable compounds for
bumpers and body panels.
Fully automated paint robot at Innovation Headquarters, Linz, Austria.
Moulded-in colour solutions
Moulded-in colour solutions enable cost reduction through
elimination of painting cycles. To assist OEMs realise
their vehicle aesthetic goals, we have the expertise and
a dedicated colour department that works with pigment
suppliers to develop narrow colour specifications for our PP
compounds. These include simulating high quality special
effects inherent in more expensive materials.
The Daimler Smart car is an example of one of the first
breakthrough moulded-in colour solutions for body
panels. Other special effect solutions include moulded-in
aluminium metallic effect for stone protectors, front grills
and other exterior aesthetic applications.
Continuing to build on success

Borealis and Borouge, working in close co-operation with Tiers, are continuously engaged in extending the possibilities of
PP and TPO compounds for automotive exterior applications that meet OEMs global specifications. These developments
focus on lower density and lighter weight materials which are uncompromising in their balanced stiffness and impact
performance, providing easier and lower cost manufacturing.

The second generation of lightweight PP compound for

Smart bumper, side panels, tailgate and hood is also
used for AMG and C-Class grills.

L ightweight material suitable for engineering plastic

replacement
M oulded-in colour
E xcellent surface aspect for unpainted parts
V ery good scratch resistance
H igh dimensional stability
Daplen EF150HP E xcellent impact/stiffness balance
Daimler Group Improved processability

Primerless bumper and tailgate cover solutions for

BMW 7 series.

E
 xcellent paint adhesion for two layer paint system
O
 ptimisation of painting cycle time and system cost
L
 ow density material enabling weight reduction
G
 ood impact and stiffness balance

Daplen EE112AE
BMW Group

Global bumper solution for a broad range of Renault-

Nissan models starting with new Renault Clio.

E xcellent surface aesthetics for both painted

and unpainted parts
V ery good processing
Weight reduction potential through thinner wall
designs
Renault
S ystem cost optimisation

Daplen EG107HP
Renault-Nissan

9
 Lightweight bumper solution for, among others,
VW Golf.

M
 aterial combination allows both ready-to-use and
open compound concept
Reduced filler content provides lighter weight solution
G
 ood flowability requiring lower injection pressure,
VW Group: VW Golf less energy input and reduced tool wear
L
 ow Coefficient of Linear Thermal Expansion (CLTE)
Daplen EF155AE for zero-gap assembly

Global bumper solution for the GM D2xx platform

including the new Opel Astra.

Very good processability and dimensional stability

Excellent behaviour at multi-axial impact
Low cycle time, low scrap rates and low system costs
High level of surface aesthetics
Adam Opel AG

Daplen EF119AE/EF120AE
General Motors

Volvo open compound painted bumpers for V40, XC60

and S60, among others.

C
 lose co-operation with the Tier 1 in formulation
fine-tuning
Low scrap rate
High quality perception
Volvo Car-Group: Volvo V40 CC Very good paintability
Shrinkage adaption is possible with material concept
Open compound EF015AE + WN501AE
Volvo

VW Tiguan and VW Crafter exterior side panels.

Superior surface aspect for unpainted parts

Improve injection moulding processability with lower
cycle time
Low CLTE providing good dimensional stability

Jochen Kastl

Daplen EH340AE
VW Group

10
Materials portfolio for exterior applications
MFR Flexural Tensile Impact, Impact,
HDT B CLTE
Density 230 C/ Modulus Strength Charpy Charpy
Grade (0.45 MPa) (30/+80 C) Typical applications
[kg/m] 2.16 kg (2 mm/min) (50 mm/min) notched notched
[C] [m/mK]
[g/10 min] [MPa] [MPa] 23C [kJ/m] 20 C [kJ/m]

Copolymers

Daplen EF015AE 895 18 800 19 35 7 68 86 Bumpers, exterior trims

Daplen EE002AE 905 11 1,000 20 65 9 76 100 Bumpers, exterior trims

Daplen EE050AE 905 11 950 20 60 10 75 100 Bumpers, exterior trims

TPO Compounds

Daplen EE103AE 950 12 1,400 19 50 7 92 72 Bumpers, exterior trims

Daplen EF155AE 950 18 1,400 18 35 5 90 74 Bumpers, exterior trims

Daplen EF005AE 950 25 1,070 16 52 6 85 65 Bumpers, exterior trims

Daplen EH104AE 970 40 1,200 16 38 5.5 80 68 Bumpers, grills, stone protectors

Daplen EE112AE 980 15 1,500 18 65 12 95 56 Bumpers, tailgate cover, exterior trims

Daplen EF119AE 990 23 1,750 19 55 7 101 50 Bumpers, exterior trims

Daplen EG107HP 995 22 1,750 20 40 6 100 70 Bumpers, rocker panels, exterior trims

Daplen EG134AE 1,010 32 1,620 18 40 4.5 100 57 Bumpers, rocker panels, exterior trims

Daplen EF150HP 1,010 22 2,100 23 29 4.5 110 54 Body panels, rocker panels, front grills

Daplen EE209AE 1,040 13 1,500 16 65 8 93 43 Bumpers, exterior trims

Daplen EF209AE 1,040 22 1,700 17 60 6.5 90 45 Bumpers, exterior trims

Daplen EH227AE 1,040 40 1,550 16 42 6 86 49 Rocker panels, exterior trims

Daplen EH340AE 1,120 43 1,900 19 12 2.9 105 46 Rocker panels, side panels and grills

Daplen ED345AE 1,150 8 2,800 20 35 3.5 117 40 Body panels, tailgate skin, exterior trims

Performance masterbatches

WN503AE 1,340 For open compound solution

WN501AE 1,350 For open compound solution

WN505AE 1,350 For open compound solution

Grade nomenclature

Daplen EE112AE

Pos. 1 Pos. 2 Pos. 3 Pos. 4-5 Pos. 6-7 Pos. 8

(Polymer type) (MFR range) (Filler content) (Numerical index) (Application index) (Production Location)
H Homopolymer B: > 0.82.5 0: 09% AE: Automotive exterior B: South America
R Random copolymer C: > 2.55 1: 1019% AI: Automotive interior C: Asia
B Block copolymer D: > 510 2: 2029% UB: Under the Bonnet U: North America
T Terpolymer E: > 1015 3: 3039% HP: High Performance
E Elastomer modified F: > 1520 4: 4049% SY: Sustainability
G Glass fibre G: > 2030 5: 5059% SF: Short Glass Fibre
C Carbon fibre reinforced H: > 3040 LF: Long Glass Fibre
M Mineral filled J: > 40100
W Other or combinations

11
 Borealis AG
Wagramer Strae 1719 A-1220 Vienna Austria
Tel. +43 1 22 400 000 Fax +43 1 22 400 333
www.borealisgroup.com
www.borealisdrivingtomorrow.com
www.borouge.com
automotive@borealisgroup.com

Borstar is a registered trademark of the Borealis Group.

Daplen, Fibremod, Borlink and Water for the World are trademarks of the Borealis Group.

Disclaimer The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borealis and Borouge extend no
warranties and make no representations as to the accuracy or completeness of the information contained herein, and assume no responsibility regarding
the consequences of its use or for any errors. It is the customers responsibility to inspect and test our products in order to satisfy himself as to the
suitability of the products for the customers particular purpose. The customer is also responsible for the appropriate, safe and legal use, processing and
handling of our products. Nothing herein shall constitute any warranty (express or implied, of merchantability, fitness for a particular purpose, compliance
with performance indicators, conformity to samples or models, non-infringement or otherwise), nor is protection from any law or patent to be inferred.
Insofar as products supplied by Borealis and Borouge are used in conjunction with third-party materials, it is the responsibility of the customer to obtain
all necessary information relating to the third-party materials and ensure that Borealis and Borouge products, when used together with these materials,
are suitable for the customers particular purpose. No liability can be accepted in respect of the use of Borealis and Borouge products in conjunction with
other materials. The information contained herein relates exclusively to our products when not used in conjunction with any third-party materials.
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