Hanwha Azdel Launches Recycled Polypropylene Composite for Automotive Applications

Korean composites supplier Hanwha Azdel has developed SuperLite S25, a thermoplastic composite combining polypropylene and long chopped fiber with significant recycled content. The material incorporates 25% post-consumer recycled polypropylene (PCR) by weight in the reinforced core, representing approximately 50% recycled PP in the resin component. Future development plans include sourcing 100% recycled glass fiber for the composite.

Recycled content PP composite offers potential for up to 50% weight savings in interior trim applications.

The 55% glass fiber-reinforced composite features a sandwiched construction with a PET scrim backside layer and an adhesive film supporting the A-surface, which consists of foam and non-woven fabric in bi-laminated or tri-laminated configurations. Hanwha Azdel offers adhesive options containing polyisocyanurate (PIR) and bio-based resin manufactured with renewable energy. The company is collaborating with suppliers to develop PP-based mono-material fabric, further advancing the solution's environmental credentials.

SuperLite S25 is commercially available for testing, evaluation, and validation. Current qualification testing examines flexural properties, peak load, slope, odor, flammability, recyclability, and fogging characteristics, with expansion capabilities available.

Target automotive applications include frunks, rear quarter trim panels, load floors, door panels, underbody panels, headliners, and stowage bins. Hanwha Azdel prototyped an interior trim panel with 12 inches (305 mm) of draw depth using a 450-gsm core, achieving up to 50% weight reduction. Additional prototypes include a frunk with 280 mm draw depth molded from 1,000-gsm SuperLite and a stowage bin with 190 mm draw depth using 1,100-gsm material.