How materials are redefining automotive innovation

At the 2026 Plastics in Electric & Autonomous Vehicles Conference held April 15-16 in Troy, Michigan, USA, Envalior experts highlighted how strategic material selection is unlocking new performance capabilities across EV charging, ADAS, lightweighting, and laser- welded components.

High-CTI Insulation Materials Enabling Safe, Reliable 800V+ Systems

Shorter charging times for electrical vehicles and avoidance of efficiency losses during AC/DC conversion in factories are pushing the demand for 800V+ charging in EVs and next-generation AI data centers.

While higher voltages offer many technical advantages, the risk of electrical failure continues to grow. Preventing arcing while ensuring long-term reliability under extreme electrical stress is essential.

Envalior’s new class of high-CTI Pocan insulation materials meets these requirements, enabling safer, more reliable high-voltage connectors with strong electrical and thermal performance, corrosion resistance, dimensional stability, and proven orange color stability.

Tepex® Thermoplastic Composites Redefining Structural Automotive Design

In a joint collaborative presentation, Röchling Automotive and Envalior showcased their award-winning thermoplastic roof cross beam for the Mercedes-Benz CLE Cabrio, demonstrating that advanced plastics can achieve the strength and durability demands of structural components.

Manufactured using Tepex® continuous fiber-reinforced composites in a single-step hybrid injection molding process, the team consolidated multiple functions (i.e., mounts, guides, bearings, and fastenings) into a single lightweight, high-strength structure. The result: reduced complexity, structural integrity, and design flexibility once thought unattainable with plastics.

“We were only able to make this work because of the teamwork with Envalior,” said Steven Wille of Röchling Automotive.

Recognized as a finalist for the 2025 JEC World Innovation Award, the project demonstrates how advanced materials can replace traditional metal solutions without compromise.

Engineered Polymers Unlock High-Strength Laser Welding for Electronics Integration

“There is growing interest in advancing laser welding as it opens new possibilities, particularly for applications where achieving sufficient laser transmission has been a challenge,” said Dr. Frank van der Burgt, Expert on Post Processing Technologies at Envalior.

Envalior is changing these challenges with materials engineered specifically for laser welding performance, including:

• PBT with improved transparency, broader processing windows, and faster cycle times without burning including transmission improved PBT, PBT blends for higher transmission and even Hydrolysis resistant grades (e.g. B3236XLT).
• Advanced PPS formulations that increase transmissivity while delivering weld strengths over 20 MPa. (Xytron G2084LT).
• An exceptionally good laser weldable PPA portfolio including flame retardant grades (e.g., ForTii T11 (FR), ForTii JTX2 (E&E))

These innovations enable stronger welds, more complex geometries, and better integration of sensitive electronics, accelerating the adoption of laser welding across automotive applications. Next to the traditional laser transmission welding, absorbing-to-absorbing laser welding opens a completely new array of possibilities such as welding impact modified PPS with high weld strengths.

Advanced Materials Enabling Thermal and Signal Integrity for ADAS Sensors

As ADAS sensors evolve, sensors are becoming smaller, more powerful, and more thermally demanding. Protecting these components from harsh environments while managing heat is increasingly challenging.

Envalior Application Development Engineer Madison Scally noted that radar systems are expected to shrink significantly over the next decade while integrating higher-performance chipsets that are more thermally demanding (i.e., heat-generating SiGe chips). This shift requires specialized materials tailored to each component:

• Radomes: low dielectric constant and loss for signal clarity
• Mid frames: radar absorbing materials to prevent interference
• Back covers: EMI shielding materials to protect electronics

Envalior’s portfolio is engineered to meet these needs, enabling reliable performance for radar, LiDAR, and camera systems in increasingly compact designs.

From structural components to high voltage safety and sensor reliability, Envalior is proving that material science is now a strategic lever for automotive performance. As OEMs push toward faster development cycles and more demanding requirements, advanced materials will be essential to staying competitive.

Learn More About Materials for Automotive

Watch TechTalk: Advances in Laser Welding