Teijin develops advanced composite materials for Formula E racing

Wuppertal, Germany – Teijin has teamed up with Germany’s herone GmbH and the UK’s Envision Racing to develop a composite wishbone which has the capability be used in a Formula E racing car using Tenax™ ThermoPlastics. This collaborative effort not only leverages cutting-edge materials and advanced manufacturing techniques but also highlights how innovative partnerships can drive sustainable solutions for the future.

The new component is specifically designed to maximize performance while minimizing weight – a crucial advantage in the highly competitive world of Formula E. By utilizing recycled materials from the aerospace industry and implementing herone’s innovative pressing process, the partners are setting a strong example of environmental consciousness and technological excellence.

Multiple demonstrator parts were produced utilizing Tenax™ ThermoPlastic UniDirectional (TPUD) tapes. The material was braided to form the rod structure of the component. Recycled offcuts from part manufacturing in the aerospace industry were used for the functional elements. Those offcuts were injection molded to sockets which are needed for load introduction into the rod structure. herone’s innovative pressing process then compression molded the braids and at the same time co-consolidated the sockets into the rod structure to form the final part. All materials in this study were based on PPS polymer – thus making it attractive for further end-of-life recycling. A perfect match for the highly innovative Formula E series and the sustainability approach of the Envision Racing team.
The wishbone is currently used in Envision Racing’s show car, which tours the world for various team sustainability initiatives and PR events.

The use of these advanced materials makes it possible to reduce weight, minimize emissions, and increase performance at the same time. The combination of design and functionality opens new possibilities for future developments in the field of motorsport and beyond. We look forward to continuing to develop innovative solutions based on thermoplastic composites together with our partners and customers.