REHAU & BMW: Forging a Stronger Connection with Innovative Connecting Rods

Leesburg, VA – REHAU INDUSTRIES LLC, a leading global polymer specialist, is quietly powering performance under the hood of some of the world’s most iconic vehicles – including BMW. While you might not see REHAU’s work, it’s a critical component in ensuring smooth, reliable engine operation. We’re talking about connecting rods – and REHAU is delivering cutting-edge polymer solutions that are changing the game. For decades, connecting rods were almost exclusively made of metal – steel, typically. Heavy, complex to manufacture, and prone to fatigue, these metal components presented ongoing challenges for automakers striving for lighter vehicles and increased efficiency. That’s where REHAU stepped in. Beyond Metal: The REHAU Advantage REHAU isn’t just another materials supplier. We’re engineers, innovators, and problem solvers. We specialize in high-performance polymers – basically, incredibly tough, incredibly versatile plastics – and we’ve been working closely with BMW for years to develop and refine polymer connecting rods that meet, and often exceed, the demands of modern engines. “It wasn’t about just replacing metal with plastic,” explains a REHAU engineer working on the BMW project. “It was about reimagining the component entirely. Polymers offer unique properties – they’re lighter, can be molded into complex shapes, and offer excellent vibration damping. We had to leverage those properties to create a connecting rod that was not only lighter but also more durable and reliable.” What Makes REHAU’s Polymer Connecting Rods Different? So, how does a plastic connecting rod stand up to the extreme forces inside an engine? It's not simply any plastic. REHAU’s solution utilizes a specially formulated polyamide composite reinforced with carbon fiber. This combination delivers: Significant Weight Reduction: Polymer rods are considerably lighter than their metal counterparts. This contributes to reduced overall vehicle weight, leading to improved fuel efficiency and performance. We're talking a noticeable difference – several pounds per engine, which adds up across an entire production run. Enhanced Vibration Damping: Polymers naturally absorb vibrations. This reduces engine noise and wear, leading to a smoother, more refined driving experience and potentially extending engine life. Think of it like built-in cushioning for critical engine parts. Optimized Design Freedom: Polymers can be molded into incredibly complex shapes. This allows REHAU to design connecting rods with optimized geometry, maximizing strength and minimizing stress concentrations. We’re not limited by the constraints of traditional metal manufacturing processes. Cost Efficiency: While the initial material cost might be higher, the streamlined manufacturing process and reduced material waste associated with polymer processing can lead to overall cost savings. Plus, fewer machining steps mean faster production times. Durability and Reliability: Extensive testing – and years of real-world use in BMW vehicles – have demonstrated that REHAU’s polymer connecting rods are just as durable and reliable as their metal counterparts. We’ve pushed these components to their limits in the lab and on the road. Collaboration with BMW: A Partnership Built on Innovation This wasn't a solo effort. REHAU’s work with BMW is a true partnership. Engineers from both companies worked hand-in-hand throughout the development process, sharing expertise and collaborating on design and testing. “BMW is committed to pushing the boundaries of automotive technology,” says a BMW spokesperson. “REHAU’s expertise in polymer materials and their willingness to collaborate made them the ideal partner for this project. We were looking for a solution that would not only reduce weight but also improve engine performance and refinement. REHAU delivered.” Beyond BMW: The Future of Polymer Connecting Rods The success of this project with BMW is opening doors for REHAU to expand its polymer connecting rod technology to other automotive manufacturers. The demand for lighter, more efficient vehicles is only going to increase, and REHAU is well-positioned to meet that demand. “We’re not just selling materials; we’re providing solutions,” says a REHAU executive. “We’re helping automakers reduce weight, improve performance, and build a more sustainable future.” REHAU INDUSTRIES LLC – A Brief Overview Located in Leesburg, Virginia, REHAU is a global leader in polymer processing, offering a wide range of products and solutions for the automotive, construction, furniture, and medical industries. With a commitment to innovation and sustainability, REHAU is dedicated to developing cutting-edge materials and technologies that improve the quality of life. You can reach them at 1501 EDWARDS FERRY RD NE, LEESBURG, VA, 20176-6680 or by phone at 313-892-5864. They are constantly working behind the scenes to improve products you use everyday, including vital automotive components. This isn’t just about making parts; it's about engineering a better tomorrow.