By working with an efficient network of specialized Tier 1 suppliers car manufacturers (OEMs),can focus on designing new vehicles and building their own brand. Tier 1 suppliers not only supply them directly with components or whole assemblies, but are also actively involved in the design, testing and implementation of innovative solutions. How do we support Original Equipment Manufacturers (OEMs) in these tasks on a daily basis?
Why choose Knauf Industries Automotive as Tier 1 supplier?
Product research and development, integration of advanced technologies and optimisation of manufacturing processes, all while adhering to strict parameters imposed by current legislation or industry standards. Companies performing OEM functions often invest heavily in the development of new technologies so that car manufacturers do not have to develop them from scratch, which, given the complexity of modern car design, would be virtually impossible. As a Tier1 manufacturer, we actively support our OEM contractors at every stage of the production of EPP and EPS automotive components with our experience, the latest production and material technologies and our own ID Lab research centre. As a result, we take an individual approach to each project and are able to tackle even the most complex technical issues.
Individual approach to the customer
The process of Knauf Industries Automotive's collaboration with OEMs is always predictable and takes place in several interrelated stages. During the initial cooperation phase, we define the main objectives of the project and the market expectations and discuss the technical specifications and quality criteria. On this basis, the scope of the project, the schedule of activities and the budget are established. Our Automotive Engineering Team then carefully analyses the consumer needs, the environmental requirements and the trends in the use of modern materials. In the second stage, we already move to design work. Initial solution concepts are developed: engineers prepare sketches and 3D models and propose innovative technological solutions using advanced materials or production methods. A key moment in the Design for Manufacturing process is the selection of appropriate materials that not only ensure the durability of the component, but also the compliance with safety, environmental and aesthetic standards.
We discuss all our suggestions with the customer, make adjustments and together choose the best solutions for individual needs. In the third stage, actual prototypes are already created and subjected to various types of testing, from computer simulations to functional and endurance tests. We check the key parameters related to safety, energy efficiency and strength of materials, as well as compliance with OEM standards. The test results are the starting point for optimisation. Once the testing phase has been successfully completed, final validation of the design by Knauf Automotive and the OEM customer takes place, after which the production phase can start. Our advanced quality control systems ensure that every component manufactured at our facilities meets the most stringent standards. Once the manufacturing process is complete, we hand over the final product to the OEM, but that is not all. We also offer after-sales support and the possibility of future modifications if required.
Advantages of working with Knauf Automotive
Cooperation with Knauf Automotive is not only a guarantee of the highest quality, but most importantly an opportunity to quickly place state-of-the-art solutions on the market, which directly contributes to competitiveness. In the manufacturing process, we incorporate modern technologies and innovative materials, such as ultra-light EPP foams that can include renewable raw materials (RELOOPP®), or EPS produced on the basis of a biomass balance (NEOPS®). Our products not only reduce the kerb weight of the vehicle but also lower its carbon footprint in line with current requirements. We apply rigorous quality control procedures at all stages of the process, from consultation to prototyping to final production. We also manufacture injection-moulded car components based on built-to-print model that are highly reliable and fulfil their function in the most demanding applications. Thus we are able to deliver a one-stop-shop service for both foams and injection.
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Regular consultations and a rapid exchange of information allow improvements to be made on an ongoing basis. All of this ensures that innovations developed jointly with OEM companies move more quickly into the marketing phase, which is crucial in the context of a rapidly changing technology. Our materials and advanced processing solutions enable cost reduction, reduce raw material consumption and minimise production waste. This not only reduces operating expenses but also has a positive impact on the environment.
Examples of success and completed projects – case studies
Knauf Industries is a reliable supplier for many renowned brands (Renault, Stellantis, Toyota, to name just a few) and we are recognized for our service and are ranked among the strategic suppliers for our commodity.
Our proven material technologies enable the production of durable and reliable vehicle interior components such as door panels, dashboard components or seat infill materials, which has already been appreciated by many OEMs around the world. Ultralight, strong and resilient foams retain their excellent performance over a long period of time, ensuring a longer car life and optimum comfort. EPP components have a so-called shape memory effect, so that they return to their previous form when pressure or impact ceases. Not only do they ensure correct body posture, but they also reduce the consequences of potential accidents. The high precision of the moulding enables the production of parts with carefully contoured shapes. The best proof can be found in our sun visors, which are manufactured with the utmost attention to detail. Depending on your carbon footprint and sustainability expectations, we are also able to manufacture components using recycled raw materials thanks to our RELOOPP® material range. It contains a defined percentage of post-consumer waste (10%, 25%, 30% of recycled content), while retaining all the properties of virgin material. Our solutions also include special EPP foams that are resistant to high temperatures and electrical punctures, which are suitable for the production of engine covers, hydrogen tanks and even housings and insulation components for batteries used in electric cars.
Knauf Industries Automotive's global reach
Knauf Industries Automotive is a global brand that is rapidly expanding its presence in key automotive markets. Thanks to the strategic locations of our manufacturing facilities, we serve customers in many countries. Close cooperation with European OEMs, stringent quality standards and advanced technology create the ideal conditions for the development of highly reliable products. And the rapidly growing Asian markets for hybrid and electric cars provide us with excellent opportunities to implement innovative solutions. We also consistently broaden our operations in Latin America and the EMEA region, among others.
Interestingly enough, our products like battery packaging are used for shipments of valuable EV batteries to North America, which is known for its high quality requirements and innovative solutions. This demonstrates our ability to perform world-class projects and offer components that meet the most stringent industry standards.
Our manufacturing footprint comprises also the raw material production for EPP (in Schwarzheide, Germany) and EPS (in Saint Ghislain, Belgium) which makes us independent from external raw material suppliers eliminating supply shortage risk.
Our global presence allows us to quickly adapt our offer to specific market conditions and transfer knowledge and technology between regions. In this way, innovative solutions developed in one region can be rapidly implemented worldwide, giving us a competitive advantage in the global automotive market.