Advanced polymers for lightweighting and metal replacement by Envalior
Last update on May 11, 2026
Designing components for e-mobility and smarter electronics increasingly requires materials that combine heat resistance, dimensional stability, electrical performance, and recyclability – often within tighter space and cost constraints than conventional designs allowed.
At Smart Plastics 2026, Envalior presented a range of engineering material solutions developed in direct collaboration with automotive and E&E manufacturers to address these compounding requirements.
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Applications presented at Smart Plastics 2026
Advanced EV steering motor insulation developed for a major automotive OEM, manufactured with Envalior’s Stanyl® PA46 material, providing high heat resistance, class H thermal insulation, high flow characteristics, and stator rigidity exceeding requirements, while enabling a more compact design. During the fair, Envalior’s Martin Burg, Advanced Development Expert, presented the latest developments in ultra-thin e-motor insulation, detailing how new solutions enable much thinner designs than conventional materials.
Robust cooling fan for AI servers made with Xytron™ PPS, offering excellent dimensional stability, rigidity, and creep performance, in addition to high thermal resistance with a maximum service temperature of up to 150ºC alongside processability benefits, such as low flash for easier injection molding.
High-speed EV bearing cage made with Stanyl® PA46 – reported as engineered to meet the higher torque, faster rotational speeds, and elevated temperatures of EV motors, delivering high stiffness, fatigue resistance, and weldline strength while reducing part deformation and improving cost efficiency.
High-voltage connectors for high-speed EV charging, which can be made with a range of grades adapted to customer needs, including Akulon® (PA66), Durethan® (PA6), and Pocan® BFN4232ZHR S1 – a halogen-free, PFAS-free flame-retardant PBT grade that combines the dimensional stability and electrical insulation of PBT with the hydrolysis resistance, creep resistance, and elongation at break in the range of PA6 and PA66, enabling greater design freedom in 800V+ charging systems.
Across these applications, Envalior's approach combines global R&D expertise with localized compounding services and tailored application support, with the stated objective of helping customers reduce time-to-market, risk, costs, and emissions. According to Envalior, this development model is designed to support manufacturers managing the concurrent pressures of e-mobility ramp-up, tightening regulatory requirements, and cost-efficient production.
“Evolving market and regulatory demands are placing increasing pressure on manufacturers to develop components that are more resilient, robust, recyclable, resistant to heat and electrical failure, and compact – all while managing ongoing cost pressures. This is driving a clear need for smarter material selection and deeper co-development partnerships. At Envalior, we work side by side with our customers at every stage of the design and manufacturing process, combining our global R&D expertise with local market knowledge to help them find the right solution more efficiently,” says Fabio Passeri, Business Development manager at Envalior Italy.
You can review grades for automotive and electronics applications and compare performance parameters directly in the Master Catalog of Plastics.