REHAU Powers BMW Performance with Advanced Connecting Rod Technology

Leesburg, VA – October 26, 2023 – REHAU INDUSTRIES LLC, a leading global specialist in polymer technology, is quietly playing a crucial role in the performance and reliability of BMW engines. While many know REHAU for its innovative solutions in windows, doors, and furniture, a significant portion of their expertise and advanced materials science is dedicated to automotive components – and specifically, the demanding world of engine internals. Today, we’re diving into how REHAU’s polymer technology is revolutionizing BMW’s connecting rods, delivering benefits in weight reduction, performance enhancement, and durability. For decades, connecting rods in high-performance engines like those found in BMW vehicles were almost exclusively made from forged steel or titanium. These materials are strong, yes, but they’re also heavy and complex to manufacture. REHAU saw an opportunity to leverage their polymer expertise to offer a lighter, more cost-effective, and equally durable solution. It wasn't about replacing metal entirely, but optimizing the design and material composition for specific parts of the connecting rod. “We didn’t come at this saying ‘we’re going to eliminate metal’,” explains a REHAU engineer working on the BMW project, who asked not to be named due to confidentiality agreements. “Our approach was, ‘where can we intelligently integrate polymers to reduce weight and improve overall performance without compromising strength or longevity?’” The Challenge: Balancing Lightness, Strength & Durability The connecting rod is a critical component within the engine. It connects the piston to the crankshaft, converting reciprocating motion into rotational force. This component is subjected to immense stress and heat during engine operation. A failure here can lead to catastrophic engine damage. Therefore, any new material or design had to meet incredibly stringent requirements. Traditional steel connecting rods, while strong, add significant weight to the rotating assembly. Reducing this weight improves engine responsiveness, acceleration, and fuel efficiency. Titanium is lighter, but expensive and difficult to work with. Polymers, particularly advanced engineered polymers developed by REHAU, offer a compelling alternative – when engineered correctly. REHAU’s Polymer Solution: A Hybrid Approach REHAU didn't just swap out metal with plastic. Their solution is a clever hybrid design. They developed a specialized polyamide composite material, reinforced with glass fibers, for specific portions of the connecting rod – primarily the connecting rod cap. The body of the rod still utilizes forged steel for maximum strength, but the cap – crucial for securely holding the crankshaft journal – is expertly crafted from REHAU's high-performance polymer. “Think of it as strategically replacing a non-critical, but still structurally important, component with a lighter-weight, equally strong material,” the REHAU engineer clarifies. "The steel rod handles the bulk of the tensile and shear forces, while the polymer cap provides secure clamping and reduces overall mass." Key Benefits & Technical Details So, what does this polymer-enhanced connecting rod actually do for BMW drivers? The benefits are significant: Weight Reduction: The polymer cap reduces the weight of each connecting rod assembly by approximately 20-30% compared to an all-steel design. This seemingly small reduction, multiplied across all connecting rods in an engine, translates to a noticeable improvement in engine performance. Improved Engine Responsiveness: Lower weight means less inertia, allowing the engine to rev more quickly and respond more sharply to throttle inputs. Enhanced Fuel Efficiency: Reducing the weight of the rotating assembly requires less energy to move, resulting in improved fuel economy. Reduced Vibration & Noise: Polymers inherently dampen vibrations, contributing to a smoother and quieter engine operation. Cost Optimization: While advanced polymers aren’t “cheap”, the optimized design and manufacturing process can lead to cost savings compared to using exotic metals like titanium. Durability & Reliability: REHAU’s polymer composite is engineered to withstand the extreme temperatures, pressures, and stresses of a high-performance engine. Rigorous testing – including fatigue testing, impact testing, and chemical resistance testing – ensures long-term reliability. The Science Behind the Polymer REHAU’s success isn’t just about using a polymer; it’s about developing a specific polymer tailored to the demands of the application. The polyamide composite used in the connecting rod caps features: High Tensile Strength: The material can withstand significant pulling forces without breaking. Excellent Fatigue Resistance: It can endure millions of cycles of stress without failing. Superior Chemical Resistance: It’s resistant to the oils, fuels, and coolants found in an engine. Low Coefficient of Thermal Expansion: It minimizes dimensional changes due to temperature fluctuations. Glass Fiber Reinforcement: The glass fibers significantly increase the material’s strength, stiffness, and dimensional stability. The Future of Polymer Integration in Automotive REHAU’s work with BMW’s connecting rods is just one example of how polymers are increasingly being used to replace or augment traditional materials in automotive applications. From lightweight body panels to advanced interior components, polymers offer a compelling combination of performance, cost-effectiveness, and sustainability. “We see a huge opportunity to further integrate polymer technology into automotive components,” says a spokesperson for REHAU INDUSTRIES LLC. “We’re not just a materials supplier; we’re a solutions provider. We work closely with automakers like BMW to identify opportunities to optimize designs, reduce weight, and improve performance using our advanced polymer expertise.” Located at 1501 Edwards Ferry Rd NE, Leesburg, VA, 20176-6680, and reachable at 313-892-5864, REHAU continues to push the boundaries of polymer technology, quietly powering the performance and efficiency of vehicles on roads around the world. While most drivers won’t realize it, REHAU’s innovative materials are playing a critical role in the driving experience.