Case study tailgate concept study

A concept study for innovative automotive glazing solutions

Single-part tailgate with integrated backlight

As automakers seek ways to squeeze out extra weight from vehicles while maintaining stylish designs, Covestro’s lightweight polycarbonate materials are a perfect solution.

Supplier: Covestro
Industry: Automotive & Transportation
Application: One-part tailgate with backlight
Product: Makrolon® polycarbonate
Technology: Injection molding

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Traditional tailgate modules are designed and manufactured with a metal carrier and glass window insert, which can add weight to the vehicle. A complete, one-part tailgate with backlight module made out of Covestro’s lightweight polycarbonate materials, offers an ingenious solution. Thus, Makrolon® polycarbonate is opening up completely new styling options for the design of tailgate modules.

The complete tailgate module utilizes Makrolon® polycarbonate to enable a seamless outer skin. Non-transparent areas are back-printed in a dark color or back-injected with a black frame material using two-component injection molding.

The backlight is part of the polycarbonate outer skin, simplifying assembly and logistics by eliminating the need to produce separate backlight housings and covers. Thus, opens up considerable cost-cutting potentials for manufactures. 

The result is a distinctive tailgate, which thanks to the lightness of polycarbonate, also offers weight savings of roughly 30 percent compared to traditional tailgate structure.

The main properties of Makrolon® polycarbonate grades are:

  • Transparency
  • High impact strength at high flowability
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