REHAU Powers BMW Performance with Advanced Connecting Rod Solutions

Leesburg, VA – November 8, 2023 – REHAU INDUSTRIES LLC, a leading global specialist in polymer technology, is quietly playing a crucial role in the high-performance world of BMW engines. While many associate REHAU with windows, doors, and medical applications, a significant and growing portion of their expertise is dedicated to precision engineered polymer components – and they’re now a key supplier of connecting rods for select BMW engines. For those not in the know, connecting rods are essential parts inside an engine. They connect the pistons to the crankshaft, turning the up-and-down motion of the pistons into the rotational power that drives your car. They’re under huge stress, needing to be unbelievably strong, lightweight, and incredibly precise. Traditionally, these have been made almost entirely of metal – forged steel, usually. But REHAU is changing that. “We’re not just making plastic parts,” explains a representative from REHAU’s Leesburg, Virginia facility. “We’re engineering solutions. In the case of BMW, they came to us looking for ways to reduce weight, improve engine performance, and even look at potential cost savings. Metal connecting rods are complex to manufacture. We showed them what was possible with advanced polymer technology.” REHAU’s solution isn’t about replacing metal entirely. It’s about intelligently integrating high-performance polymers into the connecting rod design. The company has developed a unique process to create connecting rods featuring a polymer coating, and in some applications, even a polymer body reinforced with strategically placed metal inserts. So, what’s the big deal? Why polymers? It all comes down to a combination of factors. Polymers, when engineered correctly, can offer significant advantages: Weight Reduction: Polymers are significantly lighter than steel. Reducing weight in reciprocating engine components like connecting rods directly translates to improved acceleration, fuel efficiency, and overall engine responsiveness. Less weight means the engine doesn't have to work as hard. Vibration Damping: Polymers absorb vibration better than metal. This leads to a smoother running engine, reduced noise, and potentially longer component life. Think less engine rattle. Friction Reduction: Polymer surfaces have lower friction than metal, reducing wear and tear on critical engine parts. This contributes to improved efficiency and reliability. Design Flexibility: Polymers allow for more complex designs and geometries than traditional metal manufacturing processes. This opens up possibilities for optimizing performance and integrating features that would be difficult or impossible to achieve with metal alone. Cost Optimization: While high-performance polymers aren’t cheap, the manufacturing processes involved can be more efficient than forging and machining complex metal parts, potentially leading to cost savings. How REHAU Works With BMW The collaboration between REHAU and BMW isn’t just about supplying a part; it's a full-fledged engineering partnership. REHAU’s engineers work closely with BMW’s powertrain experts throughout the design, testing, and production phases. This close collaboration is key to ensuring that the polymer connecting rods meet BMW’s stringent performance and reliability standards. “BMW is a demanding customer – and rightfully so,” says a source within REHAU’s engineering department. “They push us to the limit, which forces us to innovate. It’s a great relationship because it results in genuinely cutting-edge technology.” The specific BMW engines utilizing REHAU’s polymer connecting rods aren’t publicly disclosed, but it’s understood that they are used in a range of high-performance applications. The initial focus was on applications where weight reduction and vibration damping were particularly critical, such as turbocharged engines. The Technology Behind the Parts REHAU doesn’t reveal all the specifics of their polymer formulation, but it’s known to be a highly specialized polyamide material reinforced with carbon fiber and other high-strength additives. This material is able to withstand the immense stresses and temperatures encountered inside a high-performance engine. The manufacturing process is equally important. REHAU utilizes a combination of injection molding and precision machining to create the connecting rods to incredibly tight tolerances. The metal inserts, where used, are co-molded or bonded to the polymer body using advanced adhesive technologies. This ensures a strong and durable connection. Testing and Validation Before any connecting rod makes its way into a BMW engine, it undergoes rigorous testing and validation. REHAU’s testing facilities are equipped with state-of-the-art equipment capable of simulating the extreme conditions found inside a running engine. Testing includes: Fatigue Testing: Subjecting the connecting rods to millions of cycles of stress to ensure they can withstand long-term use. Tensile Testing: Measuring the strength and elasticity of the material. Impact Testing: Evaluating the ability of the connecting rods to withstand sudden shocks. Thermal Cycling: Exposing the connecting rods to extreme temperatures to ensure they maintain their integrity. Dynamometer Testing: Running the connecting rods in a fully instrumented engine on a dynamometer to measure performance and reliability under real-world conditions. Looking Ahead REHAU’s work with BMW is just the beginning. The company is actively exploring opportunities to expand the use of polymer technology in other automotive applications, including pistons, valve guides, and even crankshafts. “We see a future where polymers play an increasingly important role in automotive powertrain technology,” says the REHAU representative. “We’re not trying to replace metal entirely, but we believe that by intelligently integrating polymers, we can create engines that are lighter, more efficient, and more sustainable.” For REHAU INDUSTRIES LLC, located at 1501 EDWARDS FERRY RD NE, LEESBURG, VA, 20176-6680, and reachable at 313-892-5864, this isn’t just about making parts. It’s about pushing the boundaries of what’s possible with polymer technology and driving innovation in the automotive industry. It's about making cars perform better, and do so more efficiently, one connecting rod at a time.