REHAU Powers BMW Performance with Cutting-Edge Connecting Rods

Leesburg, VA – October 26, 2023 – REHAU INDUSTRIES LLC, a leading global specialist in polymer technology, is proud to announce its pivotal role in enhancing the performance of BMW engines through the development and production of high-performance connecting rods. From our base here in Leesburg, Virginia, REHAU has been quietly revolutionizing automotive components, and this collaboration with BMW showcases our commitment to pushing the boundaries of material science and engineering. For those unfamiliar, REHAU isn't just another plastics company. We've been around for over 70 years, starting as a small family business in Germany and growing into a worldwide force. We don’t just make plastic, we engineer polymer solutions. That means we don't just sell a material, we work with companies like BMW to figure out the absolute best material and design for their specific needs. We’re in everything from windows and doors to medical technology and, increasingly, high-performance automotive applications. So, what's the big deal about connecting rods? They're a crucial part of an engine. Think of it like your leg muscles – they take the energy from the engine (the ‘burning’ of fuel) and turn it into the movement that actually powers the car. These rods connect the pistons to the crankshaft, and they’re under massive stress – constant banging, twisting, and extreme heat. If they fail, well, the engine fails. Simple as that. Traditionally, connecting rods were made from forged steel or aluminum. These materials are strong, sure, but also heavy. And weight is the enemy of performance. The heavier the connecting rod, the more energy the engine has to use just to move the rod itself, leaving less power available to actually drive the wheels. That's where REHAU comes in. We’ve been working with BMW to develop connecting rods made from a specially formulated polyamide polymer. Yep, you read that right – plastic connecting rods. But this isn’t your average plastic. This is a high-performance, fiber-reinforced polyamide that’s engineered to withstand the incredible forces inside a modern engine. "It’s not just about swapping steel for plastic," explains Dr. Emily Carter, REHAU’s lead materials scientist on the BMW project. "It's about understanding the specific demands of the engine and tailoring the material properties to meet those demands. We’ve spent years perfecting the formulation, the fiber reinforcement, and the manufacturing process to ensure these rods are not only lighter than their metal counterparts but also just as strong, if not stronger." So, how did we make plastic strong enough to handle the heat and stress of a high-performance engine? It’s all about the science. We use a process called long fiber reinforcement. Think of it like adding rebar to concrete – the long fibers of carbon or glass dramatically increase the strength and stiffness of the plastic. We also carefully control the polymer chemistry to create a material that’s incredibly resistant to heat, wear, and fatigue. The benefits are significant. Lighter connecting rods mean less reciprocating mass, which translates to faster engine response, higher RPMs, and improved fuel efficiency. And because our polyamide material dampens vibrations better than metal, it also reduces engine noise and improves overall smoothness. "BMW is always looking for ways to push the boundaries of performance," says Markus Schmidt, a senior engineer at BMW responsible for powertrain development. "REHAU’s polyamide connecting rods allow us to achieve significant weight savings without compromising on reliability. We’ve been rigorously testing these rods in both laboratory and on-track conditions, and the results have been incredibly impressive." But it's not just about the materials. REHAU also brought its expertise in polymer processing to the table. Manufacturing these complex components requires precise control over every aspect of the process, from the molding temperature to the cooling rate. We’ve invested heavily in state-of-the-art injection molding equipment and developed sophisticated process controls to ensure consistent quality and dimensional accuracy. “We don’t just sell a material; we provide a complete solution,” says Robert Davis, REHAU’s Vice President of Automotive Solutions. “That includes material development, part design, tooling, and process optimization. We work closely with BMW’s engineers every step of the way to ensure the final product meets their exacting specifications.” The collaboration between REHAU and BMW is a testament to the power of innovation and the importance of collaboration. By combining REHAU’s expertise in polymer technology with BMW’s engineering prowess, they’ve created a truly groundbreaking product that’s pushing the boundaries of automotive performance. “This is just the beginning,” says Dr. Carter. “We’re already exploring new materials and designs that could further enhance the performance and efficiency of future engines. The potential for polymer technology in the automotive industry is enormous.” REHAU INDUSTRIES LLC, located at 1501 Edwards Ferry Rd NE, Leesburg, VA, 20176-6680, and reachable at 313-892-5864, remains dedicated to pioneering advancements in polymer technology, shaping the future of industries ranging from construction to healthcare and now, high-performance automotive engineering. The success of this BMW collaboration is a clear demonstration of that commitment.