Dow Automotive's innovative approach for bonding in hybrid front-end systems has officially gone into production with the launch of the new Volkswagen Polo. The Polo's new front end is an important aspect of this new model and Dow Automotive contributed here significantly. Working together with Dow Automotive, Volkswagen developed a solution that not only reduced weight, but at the same met all requirements for part rigidity and cost requirements. Weight reduction was achieved on 25 % or 1 ½ kg per part in comparison to other solutions.

The prototype for this part, first presented in 2002 and based on the Golf IV front end carrier, already displayed many of the features present on the new Polo front end: a combination of long glass fibre reinforced (LGF) polypropylene bonded with low energy substrate adhesive (LESA) to metal parts. Unlike more traditional hybrid solutions, this design incorporates a closed box section not possible with the traditional overmoulding technique, enabling maximum stiffness with minimum weight. By using BETAMATE* LESA technology, materials with low surface energies, such as polypropylene, can be bonded to dissimilar substrates without the use of pre-treatment. In addition, Dow Automotive's hybrid solution also enables the flexibility to implement design changes late in the product development phase resulting in lower tooling costs.

The hybrid concept as presented in the new Polo is a mature concept that still offers potential. Emphasizing this future potential Roland Janssen, Plastics Marketing Manager at Dow Automotive, said: "We are delighted that Volkswagen decided in favour for our technology and thus proved our approach. With our application know-how we at Dow Automotive see still great potential for further weight reduction as the central area of the concept."

Dow Automotive is a leading supplier of plastics, adhesives, sealants and other plastics-enhanced products for interior, exterior, under-the-hood, vehicle body structure and acoustical management applications. The organization serves global tier, OEM and aftermarket customers. With offices and application development centers around the world, Dow Automotive provides materials science expertise and comprehensive technical capabilities to its customers worldwide. For additional information about Dow Automotive products and services, visit www.dowautomotive.com. Dow Automotive is a business unit of The Dow Chemical Company.