Tara Olivo, Associate Editor12.11.24
Nonwoven materials are increasingly used in the automotive industry, driven by the growing need for lighter, more sustainable materials that enhance both vehicle performance and comfort. As automotive designers focus on reducing weight, improving acoustics and supporting environmental goals, nonwovens are increasingly recognized as a solution. The rise of electric vehicles (EVs) also creates new opportunities for these materials, leading suppliers and manufacturers to expect heightened demand and a significant role for nonwovens looking ahead.
“The role of nonwovens is expanding due to their versatility and adaptability: They can be made to suit new applications and new mobility concepts, but can also be adapted to the performance demands of the specific application,” says Fabian Geyer, head of sales for German nonwovens producer Sandler. “A broad range of technologies for producing such textiles expand the areas of application and offer more choice for designers and construction engineers. As such, they are ideally suited to meet new demands arising from electromobility and new vehicle designs.”
A few of the key drivers for increased usage of nonwovens in automotive applications are the need for increased fuel economy, the need for lower emissions and the need for increased sustainable materials, according to Phil Mango, nonwovens consultant, Smithers.
“The need for increased fuel economy is based on both governmental regulations as well as consumer interest,” Mango explains. “One way to increase fuel efficiency is to reduce vehicle weight. In many of the automotive uses for nonwovens, nonwovens are the lowest-weight material for a given performance requirement. Every gram of reduced weight in a vehicle increases fuel economy.”
More stringent governmental regulations are also driving the need for lower emissions, as global warming and public health issues demand lower emissions from internal combustion engines, Mango adds. “While electric vehicles will help this in the long term, short term and for heavier, diesel vehicles, new improved engines with lower tolerances in their combustion chambers require ultra clean fuel. While the U.S. and Western Europe have led the way here, even China has continually upgraded regulations in this area.”
Meanwhile, most major automobile producers have programs to improve sustainability in their production, he says. Some of the ways automakers are producing more sustainably are by replacing polyurethane foam with natural fiber-based nonwovens, replacing multicomponent (non-recyclable) plastics with mono-component nonwovens, and replacing heavyweight textiles with lighter-weight nonwovens.
In line with its philosophy, Sandler has focused on reducing component weights while still offering high functionality. Additionally, most of its nonwovens for the automotive industry are single-polymer materials, made from 100% polyester. They are fully recyclable after use and Sandler is addressing this topic in close cooperation with customers and partners.
Where it is possible, Sandler also uses recycled fibers in manufacturing. Nonwoven edge trims from its production as well as trims from die-cut parts produced by its customers are collected and sent for reprocessing, making them available for reuse in production and thereby supporting closed material cycles. Edge trims that cannot be directly reused are being collected and later used as post-production raw materials and added to fiber blends as well.
“Apart from the utilized raw materials, our nonwovens also support environmental protection during use,” Geyer explains. “They can combine different properties in a single material. Absorbers for application in engine covers, for example, not only dampen engine noise, but they also function as heat insulators and slow the cooling-off of the engine. Thereby, cold starts are prevented and fuel consumption is reduced.”
Additionally, the reduction of noise contributes to lowering unhealthy sound levels, not only for passengers inside but for pedestrians outside the vehicle. “As such, single-polymer materials offer combinations of characteristics otherwise only achievable through combinations of different products,” he continues.
Sandler’s finexus brand, which launched in September, is a patented solution for sound insulation, thermal insulation and sustainability in vehicles. They are sustainable single-polymer nonwovens made from 100% polyester. Designed for molded part applications in both the interior and exterior of passenger cars as well as commercial vehicles, finexus offers what was previously implemented using multilayer structures.
The new finexus nonwovens can be applied in a wide range of applications, from underbody to headliner and from wheel arch liner to trunk liner; with conventional drives or in electromobility. Their good flexural rigidity and formability supports customized, even complex component geometries. At the same time, the materials offer high strength, acoustic performance and resistance to high temperatures. Finexus also offers benefits in weight and installation space in vehicle designs, thus reducing the consumption of resources and fuel.
“Thanks to our technology, we can utilize up to 80% recycled content and significantly reduce the carbon footprint,” says Geyer. “The results are sustainable materials not only having a small carbon footprint but also being easily recyclable. The nonwovens, end products pressed from them, as well as trimmings generated during production can be reused for applications in the mobility sector. This way, finexus combines sustainability and efficiency in a circular economy.”
With the increase in importance of sustainability, many customers, especially on the OEM-level, expect a clear commitment to reducing emissions and the vehicle’s overall footprint, says Anže Manfreda, SVP Automotive and Condensation Solutions division at Freudenberg Performance Materials. “Furthermore, particularly on the OEM-level, there has been very strong interest in materials which support design-to-recycle approaches while retaining good cost and performance characteristics,” he adds.
Freudenberg Performance Materials, one of the largest nonwovens manufacturers globally, produces nonwovens for the automotive market that contain a significant share of recycled raw materials. The company’s spunlaid nonwovens. based on Lutradur technology for automotive carpets, insert mats and interior and trunk linings, contain up to 90% of recycled polyester. Additionally, unique multi-layer material for molded underbody panels and wheel liners are 100% recyclable and can be utilized in closed loop systems.
The company’s nonwovens for the automotive industry are also lighter than conventional materials, according to Manfreda. “They help to save fuel and reduce CO2 emissions.”
Freudenberg’s nonwovens based on Lutraflor technology for automotive carpets, insert mats and interior and trunk linings provide weight savings of up to 40% compared to conventional automotive carpets. Meanwhile, its unique multi-layer material for molded underbody panels and wheel liners enables weight savings of 15-40% compared to conventional products.
“Lightweight construction has become an important issue in automotive engineering due to governmental regulations concerning CO2 emissions,” says Manfreda.
Freudenberg Performance Materials’ nonwovens can be used very efficiently in lightweight construction. A textile underbody made of nonwoven material is substantially lighter than an injection molded underbody. With injection molding, the material has a much higher density.
Also, for acoustics solutions, OEMs require more and more weight reduction, Manfreda adds. “An intelligent design of nonwoven products, such as Freudenberg Performance Materials’ nonwoven acoustic pads, can meet this requirement. It is substantially lighter than competitive products due to the distribution of very few fibers across a lot of air,” he says.
Jones Family of Companies, which acquired Amherst, NH-based Rontex America in 2020, manufactures needlepunched nonwoven fabrics for “class A” interior trim and trunk surfaces, as well as materials designed to reduce or minimize disturbances in the NVH (Noise, Vibration and Harshness) category.
“Within the last few years, automotive manufacturers have been pursuing increasingly more innovative designs, which in turn require materials that can be customized to their unique needs,” says Steve Eisendrath, vice president of sales and marketing for the Rontex America division of Jones Family of Companies.
To meet that need, the company has developed and successfully implemented a new moldable fabric that can be configured for a perfect fit along any specific dash, floor or trunk, along with a sound/noise dampening pad for the dash and floor.
Like other nonwovens producers, Jones has also observed the trend toward sustainability, overall weight reduction and cost efficiency, especially with the rise of hybrids and EVs in the market. “The versatility of nonwoven materials provides solutions to all of these factors, with the added benefit from the structure of nonwoven fibers of providing unbeatable sound and heat insulation,” Eisendrath says.
Jones expects the demand for nonwovens to continue to grow as it has in the past few years, as “green,” lighter weight and quieter vehicles increasingly become the norm among consumers. “EVs in particular are driving a need already for nonwoven fabrics to replace other heavier, non-sustainable materials,” he says.
For its part, Autoneum, a Swiss automotive supplier that specializes in acoustic and thermal insulation, recently added to its portfolio of sustainable mono-material products made entirely from polyester and based on its existing Pure technology Propylat PET. Propylat technology was originally developed by Borgers Automotive, which Autoneum acquired in April 2023.
New regulations such as the revised End-of-Life Vehicles Directive in Europe are accelerating the automotive industry’s transition from a linear to a circular economy, and therefore, the recyclability of vehicles at the end of their service life is becoming increasingly important. This has raised the demand for automotive components that have great environmental performance across the product life cycle. Autoneum’s new 100% polyester trunk side trim supports customers in meeting their sustainability goals while providing strong durability, design flexibility, and aesthetic appeal.
Similar to its mono-material carpet systems, Autoneum’s 100% polyester trunk side trim is fully recyclable. Production cut-offs can be reclaimed, processed and reused, ensuring a closed material loop. With Autoneum’s high-value recycling concept, the recycled fibers can also be granulated and spun into new fibers, which reduces the need for virgin raw materials and thus conserves natural resources.
The carrier material is based on the lightweight Autoneum Pure technology Propylat PET and contains at least 50% recycled fibers. Like all variants of Propylat, the technology features a high proportion of recycled material and can be produced waste-free thanks to its complete vertical integration. In addition, Propylat PET consists of 100% PET and is therefore fully recyclable.
Autoneum’s sustainable concept for 100% polyester trunk components can also be applied to tailgate and other trunk trim. Due to its unique material composition, the Propylat-based trunk trim parts are lightweight and sound-absorbing, thus contributing to the reduction of tire and rear e-motor noise.
Meanwhile, Tenowo, a global nonwovens manufacturer, produces needlepunched nonwovens, binder-bonded nonwovens (UD and cross laid), thermal bonded nonwovens, spunlace and stitchbonded nonwovens under the Maliwatt, Malivlies, Multiknit and Kunit brands. Its primary applications in the automotive industry include nonwovens for various interior and exterior NVH trim parts, and eco-friendly materials for seats, headliners, door panels and trunk trim products.
Its newest products include sustainable solutions for EVs and PFAS-free finished repellent nonwovens to comply with the latest REACH standards—the regulation on the registration, evaluation, authorization and restriction of chemicals in the European Union. Moreover, its Multiknit products for foam replacement in seats are now available around the globe with local production in Europe, the U.S. and China.
Additionally, Tenowo’s sustainable product group for car seats and other industrial applications, called “Multiknit, Sustainaknit, Sustaknit and Climaknit,” has gained considerable interest from both existing and new customers, according to Detlev Käppel, head of Automotive & Industry, Tenowo Nonwovens. “The fully recyclable nonwovens can replace foam and other ‘bulky’ materials with the advantages of less VOC, good air permeability and much more,” he says.
Tenowo also recently developed new composite nonwovens made of 100% recycled carbon fibers and has identified several application areas in the automotive, aerospace and racing industries for this product. For example, Tenowo carbon nonwovens Zetacomp are currently used in Formula F2 series race cars for the seat frame and other areas. “Besides additional technical advantages, the low CO2 footprint of our products compared to traditional carbon textiles helps our customers to reach emission CO2 targets for their finished products,” Käppel says.
Another milestone for Tenowo was the decision to add a new manufacturing plant in Vietnam, which will be finished by the end of this year. The new plant’s product portfolio will target specific applications for the company’s automotive customers as well as other segments. “With that strategic move, Tenowo follows the future trends and markets in our industry to offer the best cost and product solutions for our customers,” Käppel says.
Materials produced by Japanese nonwovens producer Toray are also used in various automotive parts, but the largest nonwoven fabric application is Airlite, a sound-absorbing nonwoven fabric produced in Korea. Company executives say there is a demand for further enhancement of sound-absorbing performance due to the increase in the number of electric vehicles.
Most recently, the company has been stepping up the promotion of Gulfeng, its flame-resistant and flame-retardant material for the automotive market. Gulfeng combines flame retardance with "fire stopping" (shielding) properties. It will not rip or open holes when exposed to fire, providing a shield against the spread of flames. This prevents fire from reaching flammable objects on the other side; its shielding properties also reduce the levels of heat transfer. Gulfeng is available in assorted types, from thin 60μm paper to thick felt. The company believes there is growing interest in heat-resistant nonwovens for use around electric vehicle batteries.
“Over the past several years, demand for nonwoven fabrics has fluctuated in proportion to the number of automobiles produced in each region due to changes in the economy. However, the demand from the market is continuously expanding, especially in the keywords of sound absorption and heat resistance, and we expect the demand for more highly functional nonwoven fabrics to grow in the future,” company executives say.
Asahi Kasei has also introduced a new material solution for enhanced EV battery safety. Its flame retardant and highly flexible nonwoven fabric Lastan is an alternative to conventional materials for thermal runaway protection. It can be utilized in top covers, busbar protection sleeves, and other applications within the EV battery pack.
Although electric vehicles are becoming more common worldwide, battery safety is still a major concern for many car users. According to the latest “Asahi Kasei Automotive Consumer Survey,” 34% of non-EV owners in China see improved safety as a primary consideration in buying an electric vehicle. In this context, there is increasing demand for materials in EV battery cover applications having excellent resistance against flames and particle blasts, as well as good electrical insulation properties. While mineral-based materials are generally used as protection against thermal runaway at present, such materials tend to be heavy and brittle. Being stiff, these materials are difficult to adapt to complex shapes, making processability an issue for automotive OEMs.
Lastan is a non-mineral flame-resistant nonwoven fabric made by air baking a special acrylic fiber at 200-300°C. It is characterized by high flame resistance and good electrical insulation, which are further improved by a special coating process that also augments abrasion resistance. This allows the material to provide effective protection against particle bombardment from venting gas. With these exceptional characteristics, Lastan has been used for many years as an optimal material for failure prevention and safety in various industries.
Even when a 1300°C flame is applied, the temperature on the opposite side of Lastan remains below 400°C. While a “limiting oxygen index” (LOI) value of 27 or higher is generally considered to indicate flame retardance, this material has an LOI value of 50 or higher. In UL94 flame retardance testing, Lastan has obtained the highest rating of 5VA. No holes are formed in Lastan even when it is exposed to a flame of 1300°C for one minute. In addition to its high flame resistance, Lastan is resistant to high-pressure impact by particles of 200–500µm. It also provides electrical insulating capacity of up to 3.5kV at a thickness of 1mm.
Lastan also features outstanding processability, being highly flexible while maintaining its performance characteristics in sheets as thin as 0.8 mm. This makes it easily processed with ordinary tools, contributing to a simplified manufacturing process. Having integrated production of Lastan currently in Japan, Asahi Kasei is considering production in the U.S. and other countries in the future.
Käppel, of Tenowo, says the transformation in the automotive industry and disruption in many other related business areas have posed challenges to maintaining solid growth. “The automotive industry in Europe has still not recovered compared to its height in 2018-19,” he explains. “Moreover, the transformation towards e-mobility in Germany is delayed as a result of some political decisions to cut subsidies from one day to another. Rising energy costs and inflation add other difficulties in this regard to maintaining profitable growth for manufacturing companies.”
Additionally, many OEMs around the world are struggling to catch up in e-technology with some Chinese leading local OEMs. “In the U.S., high inventory levels of produced cars also create a headache within the Tear supply chain,” he continues. “In Asia we see especially foreign premium OEMs losing ground against some local manufacturers. Although many e-platforms of European and U.S.-based OEMs are postponed due to several reasons, Tenowo has already been awarded with different materials for NVH, underbody, interior, trunk trim and battery case applications.”
Electric vehicles will require even more NVH parts as noises in different frequencies occur. Käppel says that OEMs are still assessing the most effective ways to manage noise absorption.
“Although not every new part may use nonwovens, there are lots of new opportunities coming up in the area of fiber-based solutions for foam replacement, nonwovens for battery cases (insulation as well as high-performance non-flammable products to help to prevent a fire incident) and new NVH styles with PFAS-free repellent finishings. The final question remains about how long it takes for the European and U.S. auto industry to catch up with the technology gap compared to some Chinese competitors in terms of design, IT solutions, battery technology and cost competitiveness.”
Geyer of Sandler adds that the automotive market is characterized by vigorous competition, but also by innovation and further development. “Economic fluctuations do present the industry—as indeed any other sector—with challenges,” he explains. “Shortages in raw materials, components, and freight space; fluctuations in raw material prices, forwarding costs, and, last but not least, energy costs have created a difficult situation for suppliers to the automotive industry, but also for OEMs. The entry of new competitors adds more challenges. Innovation in terms of design, sustainability as well as adaptation to new regulatory requirements and above all cooperation along the supply chain to achieve these goals will be key moving forward.”
Manufacturers in the automotive industry are faced with a changing market due to new competitors, particularly from Asia, increased requirements regarding sustainability from both consumers and government regulation, as well as consistently high standards for vehicle design and driving comfort.
“Owing to the versatility of nonwovens, their adaptability and ability to combine function and sustainability, they will continue to be a go-to-material for automotive manufacturers,” Geyer says. “And joint developments will continue to open up new possibilities and areas of application.”
While the future use of nonwovens is dependent on the health and growth of the overall automotive industry, Mango, the Smithers consultant, says it is inevitable that nonwovens use will increase at an above-average rate in the future.
“With major drivers in sustainability and fuel economy (or miles per charge for EVs), nonwovens are the only currently available class of materials capable of addressing both of these major drivers,” he says. “Timing for this significant growth of nonwovens usage in automotive components may vary depending on automotive industry growth, nonwoven product development and nonwoven availability, but this growth is inevitable.”
“The role of nonwovens is expanding due to their versatility and adaptability: They can be made to suit new applications and new mobility concepts, but can also be adapted to the performance demands of the specific application,” says Fabian Geyer, head of sales for German nonwovens producer Sandler. “A broad range of technologies for producing such textiles expand the areas of application and offer more choice for designers and construction engineers. As such, they are ideally suited to meet new demands arising from electromobility and new vehicle designs.”
A few of the key drivers for increased usage of nonwovens in automotive applications are the need for increased fuel economy, the need for lower emissions and the need for increased sustainable materials, according to Phil Mango, nonwovens consultant, Smithers.
“The need for increased fuel economy is based on both governmental regulations as well as consumer interest,” Mango explains. “One way to increase fuel efficiency is to reduce vehicle weight. In many of the automotive uses for nonwovens, nonwovens are the lowest-weight material for a given performance requirement. Every gram of reduced weight in a vehicle increases fuel economy.”
More stringent governmental regulations are also driving the need for lower emissions, as global warming and public health issues demand lower emissions from internal combustion engines, Mango adds. “While electric vehicles will help this in the long term, short term and for heavier, diesel vehicles, new improved engines with lower tolerances in their combustion chambers require ultra clean fuel. While the U.S. and Western Europe have led the way here, even China has continually upgraded regulations in this area.”
Sandler’s new finexus brand is a patented solution for sound insulation, thermal insulation and sustainability in vehicles.
Meanwhile, most major automobile producers have programs to improve sustainability in their production, he says. Some of the ways automakers are producing more sustainably are by replacing polyurethane foam with natural fiber-based nonwovens, replacing multicomponent (non-recyclable) plastics with mono-component nonwovens, and replacing heavyweight textiles with lighter-weight nonwovens.
In line with its philosophy, Sandler has focused on reducing component weights while still offering high functionality. Additionally, most of its nonwovens for the automotive industry are single-polymer materials, made from 100% polyester. They are fully recyclable after use and Sandler is addressing this topic in close cooperation with customers and partners.
Where it is possible, Sandler also uses recycled fibers in manufacturing. Nonwoven edge trims from its production as well as trims from die-cut parts produced by its customers are collected and sent for reprocessing, making them available for reuse in production and thereby supporting closed material cycles. Edge trims that cannot be directly reused are being collected and later used as post-production raw materials and added to fiber blends as well.
“Apart from the utilized raw materials, our nonwovens also support environmental protection during use,” Geyer explains. “They can combine different properties in a single material. Absorbers for application in engine covers, for example, not only dampen engine noise, but they also function as heat insulators and slow the cooling-off of the engine. Thereby, cold starts are prevented and fuel consumption is reduced.”
Additionally, the reduction of noise contributes to lowering unhealthy sound levels, not only for passengers inside but for pedestrians outside the vehicle. “As such, single-polymer materials offer combinations of characteristics otherwise only achievable through combinations of different products,” he continues.
Sandler’s finexus brand, which launched in September, is a patented solution for sound insulation, thermal insulation and sustainability in vehicles. They are sustainable single-polymer nonwovens made from 100% polyester. Designed for molded part applications in both the interior and exterior of passenger cars as well as commercial vehicles, finexus offers what was previously implemented using multilayer structures.
The new finexus nonwovens can be applied in a wide range of applications, from underbody to headliner and from wheel arch liner to trunk liner; with conventional drives or in electromobility. Their good flexural rigidity and formability supports customized, even complex component geometries. At the same time, the materials offer high strength, acoustic performance and resistance to high temperatures. Finexus also offers benefits in weight and installation space in vehicle designs, thus reducing the consumption of resources and fuel.
“Thanks to our technology, we can utilize up to 80% recycled content and significantly reduce the carbon footprint,” says Geyer. “The results are sustainable materials not only having a small carbon footprint but also being easily recyclable. The nonwovens, end products pressed from them, as well as trimmings generated during production can be reused for applications in the mobility sector. This way, finexus combines sustainability and efficiency in a circular economy.”
With the increase in importance of sustainability, many customers, especially on the OEM-level, expect a clear commitment to reducing emissions and the vehicle’s overall footprint, says Anže Manfreda, SVP Automotive and Condensation Solutions division at Freudenberg Performance Materials. “Furthermore, particularly on the OEM-level, there has been very strong interest in materials which support design-to-recycle approaches while retaining good cost and performance characteristics,” he adds.
Freudenberg Performance Materials, one of the largest nonwovens manufacturers globally, produces nonwovens for the automotive market that contain a significant share of recycled raw materials. The company’s spunlaid nonwovens. based on Lutradur technology for automotive carpets, insert mats and interior and trunk linings, contain up to 90% of recycled polyester. Additionally, unique multi-layer material for molded underbody panels and wheel liners are 100% recyclable and can be utilized in closed loop systems.
The company’s nonwovens for the automotive industry are also lighter than conventional materials, according to Manfreda. “They help to save fuel and reduce CO2 emissions.”
Freudenberg’s nonwovens based on Lutraflor technology for automotive carpets, insert mats and interior and trunk linings provide weight savings of up to 40% compared to conventional automotive carpets. Meanwhile, its unique multi-layer material for molded underbody panels and wheel liners enables weight savings of 15-40% compared to conventional products.
“Lightweight construction has become an important issue in automotive engineering due to governmental regulations concerning CO2 emissions,” says Manfreda.
Freudenberg Performance Materials’ nonwovens can be used very efficiently in lightweight construction. A textile underbody made of nonwoven material is substantially lighter than an injection molded underbody. With injection molding, the material has a much higher density.
Also, for acoustics solutions, OEMs require more and more weight reduction, Manfreda adds. “An intelligent design of nonwoven products, such as Freudenberg Performance Materials’ nonwoven acoustic pads, can meet this requirement. It is substantially lighter than competitive products due to the distribution of very few fibers across a lot of air,” he says.
New Solutions
As the automotive industry continues to evolve, so does the demand for advanced materials that can meet the growing needs of both manufacturers and consumers.Jones Family of Companies, which acquired Amherst, NH-based Rontex America in 2020, manufactures needlepunched nonwoven fabrics for “class A” interior trim and trunk surfaces, as well as materials designed to reduce or minimize disturbances in the NVH (Noise, Vibration and Harshness) category.
“Within the last few years, automotive manufacturers have been pursuing increasingly more innovative designs, which in turn require materials that can be customized to their unique needs,” says Steve Eisendrath, vice president of sales and marketing for the Rontex America division of Jones Family of Companies.
To meet that need, the company has developed and successfully implemented a new moldable fabric that can be configured for a perfect fit along any specific dash, floor or trunk, along with a sound/noise dampening pad for the dash and floor.
Like other nonwovens producers, Jones has also observed the trend toward sustainability, overall weight reduction and cost efficiency, especially with the rise of hybrids and EVs in the market. “The versatility of nonwoven materials provides solutions to all of these factors, with the added benefit from the structure of nonwoven fibers of providing unbeatable sound and heat insulation,” Eisendrath says.
Jones expects the demand for nonwovens to continue to grow as it has in the past few years, as “green,” lighter weight and quieter vehicles increasingly become the norm among consumers. “EVs in particular are driving a need already for nonwoven fabrics to replace other heavier, non-sustainable materials,” he says.
For its part, Autoneum, a Swiss automotive supplier that specializes in acoustic and thermal insulation, recently added to its portfolio of sustainable mono-material products made entirely from polyester and based on its existing Pure technology Propylat PET. Propylat technology was originally developed by Borgers Automotive, which Autoneum acquired in April 2023.
Autoneum’s new 100% polyester trunk side trim.
New regulations such as the revised End-of-Life Vehicles Directive in Europe are accelerating the automotive industry’s transition from a linear to a circular economy, and therefore, the recyclability of vehicles at the end of their service life is becoming increasingly important. This has raised the demand for automotive components that have great environmental performance across the product life cycle. Autoneum’s new 100% polyester trunk side trim supports customers in meeting their sustainability goals while providing strong durability, design flexibility, and aesthetic appeal.
Similar to its mono-material carpet systems, Autoneum’s 100% polyester trunk side trim is fully recyclable. Production cut-offs can be reclaimed, processed and reused, ensuring a closed material loop. With Autoneum’s high-value recycling concept, the recycled fibers can also be granulated and spun into new fibers, which reduces the need for virgin raw materials and thus conserves natural resources.
The carrier material is based on the lightweight Autoneum Pure technology Propylat PET and contains at least 50% recycled fibers. Like all variants of Propylat, the technology features a high proportion of recycled material and can be produced waste-free thanks to its complete vertical integration. In addition, Propylat PET consists of 100% PET and is therefore fully recyclable.
Autoneum’s sustainable concept for 100% polyester trunk components can also be applied to tailgate and other trunk trim. Due to its unique material composition, the Propylat-based trunk trim parts are lightweight and sound-absorbing, thus contributing to the reduction of tire and rear e-motor noise.
Meanwhile, Tenowo, a global nonwovens manufacturer, produces needlepunched nonwovens, binder-bonded nonwovens (UD and cross laid), thermal bonded nonwovens, spunlace and stitchbonded nonwovens under the Maliwatt, Malivlies, Multiknit and Kunit brands. Its primary applications in the automotive industry include nonwovens for various interior and exterior NVH trim parts, and eco-friendly materials for seats, headliners, door panels and trunk trim products.
Its newest products include sustainable solutions for EVs and PFAS-free finished repellent nonwovens to comply with the latest REACH standards—the regulation on the registration, evaluation, authorization and restriction of chemicals in the European Union. Moreover, its Multiknit products for foam replacement in seats are now available around the globe with local production in Europe, the U.S. and China.
Additionally, Tenowo’s sustainable product group for car seats and other industrial applications, called “Multiknit, Sustainaknit, Sustaknit and Climaknit,” has gained considerable interest from both existing and new customers, according to Detlev Käppel, head of Automotive & Industry, Tenowo Nonwovens. “The fully recyclable nonwovens can replace foam and other ‘bulky’ materials with the advantages of less VOC, good air permeability and much more,” he says.
Tenowo also recently developed new composite nonwovens made of 100% recycled carbon fibers and has identified several application areas in the automotive, aerospace and racing industries for this product. For example, Tenowo carbon nonwovens Zetacomp are currently used in Formula F2 series race cars for the seat frame and other areas. “Besides additional technical advantages, the low CO2 footprint of our products compared to traditional carbon textiles helps our customers to reach emission CO2 targets for their finished products,” Käppel says.
Another milestone for Tenowo was the decision to add a new manufacturing plant in Vietnam, which will be finished by the end of this year. The new plant’s product portfolio will target specific applications for the company’s automotive customers as well as other segments. “With that strategic move, Tenowo follows the future trends and markets in our industry to offer the best cost and product solutions for our customers,” Käppel says.
Materials produced by Japanese nonwovens producer Toray are also used in various automotive parts, but the largest nonwoven fabric application is Airlite, a sound-absorbing nonwoven fabric produced in Korea. Company executives say there is a demand for further enhancement of sound-absorbing performance due to the increase in the number of electric vehicles.
Most recently, the company has been stepping up the promotion of Gulfeng, its flame-resistant and flame-retardant material for the automotive market. Gulfeng combines flame retardance with "fire stopping" (shielding) properties. It will not rip or open holes when exposed to fire, providing a shield against the spread of flames. This prevents fire from reaching flammable objects on the other side; its shielding properties also reduce the levels of heat transfer. Gulfeng is available in assorted types, from thin 60μm paper to thick felt. The company believes there is growing interest in heat-resistant nonwovens for use around electric vehicle batteries.
“Over the past several years, demand for nonwoven fabrics has fluctuated in proportion to the number of automobiles produced in each region due to changes in the economy. However, the demand from the market is continuously expanding, especially in the keywords of sound absorption and heat resistance, and we expect the demand for more highly functional nonwoven fabrics to grow in the future,” company executives say.
Asahi Kasei has also introduced a new material solution for enhanced EV battery safety. Its flame retardant and highly flexible nonwoven fabric Lastan is an alternative to conventional materials for thermal runaway protection. It can be utilized in top covers, busbar protection sleeves, and other applications within the EV battery pack.
Although electric vehicles are becoming more common worldwide, battery safety is still a major concern for many car users. According to the latest “Asahi Kasei Automotive Consumer Survey,” 34% of non-EV owners in China see improved safety as a primary consideration in buying an electric vehicle. In this context, there is increasing demand for materials in EV battery cover applications having excellent resistance against flames and particle blasts, as well as good electrical insulation properties. While mineral-based materials are generally used as protection against thermal runaway at present, such materials tend to be heavy and brittle. Being stiff, these materials are difficult to adapt to complex shapes, making processability an issue for automotive OEMs.
Lastan is a non-mineral flame-resistant nonwoven fabric made by air baking a special acrylic fiber at 200-300°C. It is characterized by high flame resistance and good electrical insulation, which are further improved by a special coating process that also augments abrasion resistance. This allows the material to provide effective protection against particle bombardment from venting gas. With these exceptional characteristics, Lastan has been used for many years as an optimal material for failure prevention and safety in various industries.
Even when a 1300°C flame is applied, the temperature on the opposite side of Lastan remains below 400°C. While a “limiting oxygen index” (LOI) value of 27 or higher is generally considered to indicate flame retardance, this material has an LOI value of 50 or higher. In UL94 flame retardance testing, Lastan has obtained the highest rating of 5VA. No holes are formed in Lastan even when it is exposed to a flame of 1300°C for one minute. In addition to its high flame resistance, Lastan is resistant to high-pressure impact by particles of 200–500µm. It also provides electrical insulating capacity of up to 3.5kV at a thickness of 1mm.
Asahi Kasei recently introduced a flame-retardant and highly flexible nonwoven called Lastan.
Lastan also features outstanding processability, being highly flexible while maintaining its performance characteristics in sheets as thin as 0.8 mm. This makes it easily processed with ordinary tools, contributing to a simplified manufacturing process. Having integrated production of Lastan currently in Japan, Asahi Kasei is considering production in the U.S. and other countries in the future.
Challenging Times
Challenges in the automotive industry—such as global supply chain disruptions, the shift toward electric vehicles, increasing material costs and stricter environmental regulations—are also impacting nonwoven manufacturers.Käppel, of Tenowo, says the transformation in the automotive industry and disruption in many other related business areas have posed challenges to maintaining solid growth. “The automotive industry in Europe has still not recovered compared to its height in 2018-19,” he explains. “Moreover, the transformation towards e-mobility in Germany is delayed as a result of some political decisions to cut subsidies from one day to another. Rising energy costs and inflation add other difficulties in this regard to maintaining profitable growth for manufacturing companies.”
Additionally, many OEMs around the world are struggling to catch up in e-technology with some Chinese leading local OEMs. “In the U.S., high inventory levels of produced cars also create a headache within the Tear supply chain,” he continues. “In Asia we see especially foreign premium OEMs losing ground against some local manufacturers. Although many e-platforms of European and U.S.-based OEMs are postponed due to several reasons, Tenowo has already been awarded with different materials for NVH, underbody, interior, trunk trim and battery case applications.”
Electric vehicles will require even more NVH parts as noises in different frequencies occur. Käppel says that OEMs are still assessing the most effective ways to manage noise absorption.
“Although not every new part may use nonwovens, there are lots of new opportunities coming up in the area of fiber-based solutions for foam replacement, nonwovens for battery cases (insulation as well as high-performance non-flammable products to help to prevent a fire incident) and new NVH styles with PFAS-free repellent finishings. The final question remains about how long it takes for the European and U.S. auto industry to catch up with the technology gap compared to some Chinese competitors in terms of design, IT solutions, battery technology and cost competitiveness.”
Geyer of Sandler adds that the automotive market is characterized by vigorous competition, but also by innovation and further development. “Economic fluctuations do present the industry—as indeed any other sector—with challenges,” he explains. “Shortages in raw materials, components, and freight space; fluctuations in raw material prices, forwarding costs, and, last but not least, energy costs have created a difficult situation for suppliers to the automotive industry, but also for OEMs. The entry of new competitors adds more challenges. Innovation in terms of design, sustainability as well as adaptation to new regulatory requirements and above all cooperation along the supply chain to achieve these goals will be key moving forward.”
Manufacturers in the automotive industry are faced with a changing market due to new competitors, particularly from Asia, increased requirements regarding sustainability from both consumers and government regulation, as well as consistently high standards for vehicle design and driving comfort.
“Owing to the versatility of nonwovens, their adaptability and ability to combine function and sustainability, they will continue to be a go-to-material for automotive manufacturers,” Geyer says. “And joint developments will continue to open up new possibilities and areas of application.”
While the future use of nonwovens is dependent on the health and growth of the overall automotive industry, Mango, the Smithers consultant, says it is inevitable that nonwovens use will increase at an above-average rate in the future.
“With major drivers in sustainability and fuel economy (or miles per charge for EVs), nonwovens are the only currently available class of materials capable of addressing both of these major drivers,” he says. “Timing for this significant growth of nonwovens usage in automotive components may vary depending on automotive industry growth, nonwoven product development and nonwoven availability, but this growth is inevitable.”
