REHAU Powers BMW Performance with Cutting-Edge Connecting Rod Technology

Leesburg, VA – October 26, 2023 – REHAU INDUSTRIES LLC, a leading global provider of polymer solutions, is proud to announce its pivotal role in enhancing the performance and durability of BMW engines through the supply of high-performance connecting rods. Operating out of its Leesburg, Virginia facility, REHAU has become a trusted partner to automotive giants like BMW, delivering precision-engineered components that push the boundaries of engine technology. For decades, REHAU has been quietly innovating in the realm of polymer science. While many know the name for windows, doors, and building materials, fewer realize the extensive expertise REHAU possesses in developing highly specialized, high-performance polymers for demanding industrial applications. The company’s dedication to research and development, coupled with a state-of-the-art manufacturing facility in Leesburg, allows REHAU to tackle complex engineering challenges and deliver solutions that consistently exceed expectations. The Challenge: Demanding Engine Performance & Weight Reduction Modern engines, especially those powering high-performance vehicles like BMWs, are under immense stress. They need to withstand extreme temperatures, high combustion pressures, and constant cyclical loading. Traditionally, connecting rods – the crucial components linking the piston to the crankshaft – have been made of forged steel or aluminum alloys. These materials are strong, but also heavy. BMW, known for its commitment to driving dynamics and efficiency, was looking for a way to reduce weight in its engines without sacrificing strength or reliability. Lighter connecting rods mean less reciprocating mass, leading to faster engine response, improved fuel economy, and increased horsepower. The challenge was finding a material and manufacturing process that could meet these demanding requirements. REHAU’s Solution: Polymer Connecting Rods – A Game Changer REHAU’s engineers rose to the occasion. Leveraging their deep understanding of polymer chemistry and processing, they developed a revolutionary connecting rod made from a specially formulated polyamide composite material. This isn’t your average plastic. This is a highly engineered material, reinforced with long glass fibers, providing exceptional strength, stiffness, and fatigue resistance. “We didn’t just take a standard polymer and say ‘let’s make a connecting rod,’” explains a lead engineer at REHAU’s Leesburg facility. “We spent years developing a custom formulation specifically tailored to the extreme demands of a BMW engine. We focused on optimizing the material's properties – its tensile strength, its resistance to creep, its ability to withstand high temperatures, and its dimensional stability.” Key Advantages of REHAU’s Polymer Connecting Rods: Significant Weight Reduction: REHAU’s polymer connecting rods are substantially lighter than their traditional metal counterparts – up to 30% in some applications. This reduction in reciprocating mass translates directly into improved engine performance. Enhanced Performance: The lighter weight allows the engine to rev more quickly and efficiently, leading to faster acceleration and a more responsive driving experience. Improved Fuel Economy: Reduced weight also contributes to improved fuel efficiency, helping BMW meet increasingly stringent emissions standards. Superior Fatigue Resistance: The polymer material is inherently resistant to fatigue, meaning it can withstand millions of cycles of stress without failing. Dimensional Stability: The material maintains its shape and dimensions under varying temperatures and loads, ensuring consistent engine performance. Cost-Effectiveness: While initial material costs may be higher than some metals, the overall cost of manufacturing and assembly can be reduced through streamlined processes and reduced machining requirements. The Manufacturing Process: Precision and Control REHAU's success isn't just about the material itself; it's also about the manufacturing process. The connecting rods are produced using a highly sophisticated injection molding process, conducted at the company's Leesburg facility. “We have invested heavily in state-of-the-art injection molding machines and quality control equipment,” says the plant manager. “We use advanced process monitoring and control techniques to ensure that every connecting rod meets BMW’s exacting specifications.” The process involves precisely injecting molten polymer into a meticulously designed mold. The mold is then cooled, and the finished connecting rod is removed. Each rod undergoes rigorous inspection and testing to verify its dimensions, strength, and durability. This includes non-destructive testing methods, such as ultrasonic inspection, to detect any internal flaws. REHAU & BMW: A Partnership Built on Innovation The collaboration between REHAU and BMW is a testament to the power of innovation and partnership. BMW’s engineers worked closely with REHAU’s materials scientists and manufacturing experts throughout the development process. This collaborative approach ensured that the polymer connecting rods not only met BMW’s performance requirements but also seamlessly integrated into their engine assembly process. “BMW is a demanding customer, and we wouldn’t have it any other way,” says a sales manager at REHAU. “Their commitment to quality and performance pushes us to constantly improve our materials and processes.” The polymer connecting rods are currently being used in a range of BMW engines, and the company is exploring opportunities to expand the use of this technology in other vehicle platforms. Looking Ahead: The Future of Automotive Materials REHAU’s success with polymer connecting rods highlights the growing potential of advanced polymers in the automotive industry. As manufacturers strive to reduce weight, improve fuel efficiency, and enhance performance, polymers are playing an increasingly important role. REHAU INDUSTRIES LLC, with its commitment to innovation and its expertise in polymer science, is poised to remain at the forefront of this exciting trend. The company continues to invest in research and development, exploring new materials and manufacturing processes that will shape the future of automotive materials. Contact: REHAU INDUSTRIES LLC 1501 EDWARDS FERRY RD NE LEESBURG, VA 20176-6680 313-892-5864