
Case Study: Replacing an Aluminium Engine Cover with Reinforced PA6
A worked calculation showing 42% weight reduction and 28% lower piece cost, plus the three metrics that must be validated.
Real selection logic broken down by part: duty cycle, failure mode, material route and validation checklist.

A worked calculation showing 42% weight reduction and 28% lower piece cost, plus the three metrics that must be validated.

Low cost, low odour and easy processing are hard requirements in interiors, and the split between PP-TD20 and PP+EPDM is clear-cut.

A bumper sees low-speed impact, car washes, sun load and paint. The compound needs toughening, weathering and paintability together.

Large thin-wall parts value stiffness, dimensional stability and low odour most — a combination PP-TD20 is hard to beat.

Once flame rating, wall thickness and appearance are fixed, usually only one or two candidates remain.

30% glass fibre reinforced: tensile strength 165 MPa, flexural modulus 8500 MPa, notched impact 11 kJ/m², for load-bearing parts and power tool housings.
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Glass fibre reinforced and impact modified: tensile strength 155 MPa, notched impact 8 kJ/m² at -30 °C, for power tools, garden equipment and industrial housings.
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Glass fibre reinforcement combined with elastomer toughening: tensile strength 140 MPa, notched impact 18 kJ/m², for drop-tested and shock-loaded parts.
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EPDM toughened with talc filling; notched impact 8 kJ/m² at -30 °C (35 kJ/m² at 23 °C), used for bumpers, exterior trim and outdoor products.
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