New Daimler GLE lightweight front-end module produced with Borealis Fibremod™

The new Daimler GLE launched in the North American market in September 2018 is the first model to feature a front-end module developed with over-moulded composite technology. Borealis supported the realization of this project with Daimler, in close cooperation with Germany-based Tier One Valeo. The project concept benefited from a strong external development network of several partners, including Bond Laminates and Engel.

Valeo selected Borealis Fibremod™ GB477HP, a 40% short glass fibre material, as the best alternative solution for the over-moulding of this application. This innovative grade was originally launched in 2017 and has already been deployed in traditional front end modules for several vehicles, including the Audi TT and Q7 as well as the Renault Laguna.

Fibremod GB477HP provided just the right flexibility and design freedom for Valeo to develop a new front-end module concept that enables functional integration of the air ducts. This innovative solution has generated a significant overall weight reduction of 30% when compared to previous designs and best material alternatives.

The project capitalized on the expertise and experience of the global Borealis automotive team. While technicians supported project development in Germany and France, the US-based team facilitated the transfer and start of production at Valeo operations in Mexico.

Another project milestone is expected during the second quarter of 2019, at which time the transfer of production of Fibremod GB477HPU will take place from Borealis facilities in Europe to the new Borealis compounding plant in Taylorsville, North Carolina. The transfer will ensure the global availability of Fibremod GB477HPU from Borealis and Borouge locations in Europe, the United States, Brazil, and China.