The 'Smart' Car: A New Milestone for Plastics in Auto

The development of the 'Smart' car, the first car with an all-plastic
chassis, represents a revolution in the automotive industry in almost every
respect. From design through to assembly, this car is a unique concept that
could have big implications for future generations of motor vehicles and
the materials used to make them. Here, David Platt, Senior Industry Analyst
at Frost & Sullivan, (http://transportation.frost.com) talks about the
industry.

A Revolutionary Vehicle

The development of the 'Smart' car, the first car with an all-plastic
chassis, represents a revolution in the automotive industry in almost every
respect. From design through to assembly, this car is a unique concept that
could have big implications for future generations of motor vehicles and
the materials used to make them.

The first 'Smart' car came off the production lines in late 1997 at a
factory in Hambach, France, near the German border. The joint owners of the
Micro Compact Car project, Mercedes-Benz and Swiss company SMH, the makers
of Swatch watches, plan for production of 200,000 vehicles in 2001. There
are three basic models on offer, known as Pure, Pulse and Passion, which
all use a Mercedes-Benz 3-cylinder, 600cc turbo engine. There are also
plans to introduce a Roadster model in the near future. The 'Smart' car can
manage 50-60mpg with a top speed of 87mph.

The Crucial Differences

The manufacture and assembly of the 'Smart' car differs in many ways from
other vehicles currently on the road.

First of all, the production site itself reflects a new principle. Unlike
existing systems, in which parts are shipped from far away, Smart
components will all be produced and assembled under one roof. A radial
assembly axis crosslinks system suppliers, including plastic chassis
producer Dynamit Nobel Kunststoff GmbH, which will injection mould the
large parts using an initial ten machines with a clamping force of
1,300-4,000 t. Also, because of the Smart plant's rational set-up, the
entire car can be produced in a record four hours and dismantled in two
hours.

The 'Smart' car is also the first vehicle to use plastics for the chassis
and body panels. GE Plastics Xenoy PC/PBT blend is the material chosen for
manufacture of these parts. The sophisticated construction developed by
Dynamit Nobel in co-operation with Ymos, facilitates the use of so-called
'hang on' parts. As the chassis is bolted rather than welded onto the steel
frame, parts such as fenders can be switched for those of a different
colour, for example. Owners can also clip in new seats and seat covers,
door linings or cockpit elements to reflect different outfits or tastes.
This technology breakthrough is known as Customised Bodypanel System (CBS).

Along with the body system, Dynamit Nobel is also supplying a number of
visible and invisible car components, including parts of the door- and
wheel cladding, special attachment clamps for the chassis and a "crashbox"
for fore and aft, which absorbs energy in the event of a minor collision.

A Boost for Engineering Plastics

The use of PC/PBT blends for manufacture of the chassis and body panels of
the 'Smart' car should spark increased interest in engineering plastics for
automotive applications. This car has demonstrated that the replacement of
metal with body parts made of engineering thermoplastics benefits car
manufacturers as well as the motorist. Manufacturers can reduce assembly
time and tooling costs by using the new plastic processing technologies. At
the same time, the significant weight reduction afforded by plastic body
parts leads to lower fuel consumption for the motorist.

Finally, the revolutionary design of the 'Smart' car means that at
end-of-life around ninety percent of the car is recyclable, a significant
improvement on what is currently being achieved. Following the introduction
of the EU End-of-Life Vehicle directive in 2000, recycling aspects will in
future receive much greater prominence by car designers and manufacturers.