[E90Fleet]

The front side panel on the new BMW 3 Series Coupé made of plastic – to be precise an innovative thermoplastic material reducing the weight of the component by 50 per cent compared with a side panel made of steel.

This alone reduces the weight of the new 3 Series Coupé by approximately three kilos. And since this progress is achieved around the front axle, it benefits the car’s driving dynamics in full: Thanks to the light material used at the front, we see not only a reduction in the overall weight of the vehicle, but also an improvement of axle load distribution achieving an ideal ratio of 50 : 50 now made possible even more easily.

This changeover from steel to high-tech plastics has not had any effects on production, with the plastic side panels still being integrated online, that is directly, into the painting process, without requiring any special assembly procedures. Contrary to former plastic components, they no longer have to be painted separately and subsequently assembled. Rather, the new plastic panels are able to go through the normal painting process together with the overall body-in-white.

And thanks to their high level of thermal resistance as well as their optimised longitudinal elongation and uptake of moisture, the side panels also provide the same looks and optical effects as onventional steel components after having been painted.

The new material also offers greater freedom in design, being easier to mould and shape than steel – an important factor giving the designer new freedom in the design process. Another major feature which has already offered significant customer benefits in the development of reversible bumpers is that the plastic side panels are largely resistant to minor bumps and impacts, the material returning to its original shape after minor deformation.

Collisions at low speeds, for example when manoeuvring in a car park, therefore hardly leave any lasting traces behind.

[Bimmerista]

This refers to the front pannel over the front wheels

[Jason]

Originally Posted by Bimmerista

This refers to the front pannel over the front wheels

Yup. These front sidepanels.

[Craigar]

Alot of cars do this. You can't tell.

[ksfrogman]

I was very interested in the use of plastics when Pontiac use them for its Fiero. However, I also recall reading that with repeated thermal heating and cooling, these panels shrunk or warped. I hope plastics technology is much better now than it was then.

[RichReg]

Originally Posted by Jason

Yup. These front sidepanels.

Uhhh...just curious,
where did you get that pic?

[Jason]

Originally Posted by RichReg

Uhhh...just curious,
where did you get that pic?

Rich, I was invited to the E92 coupe press event in Germany of course I WISH.

But those were taken at a German E92 press event - pics here - http://www.e90post.com/forums/showthread.php?t=18347

[Jason]

Look, proof that it's super light

[goldminer]

Originally Posted by Bimmerista

This refers to the front pannel over the front wheels

Front side panels??? When did they stop calling these things fenders? I couldn't figure out what part you were talking about until I got to the pictures.

[Bimmerista]

Fender!! That's the word I was looking for

[agarbati]

So Saturn was onto something all along!

[moO moO nEL]

now you can kick the fender without leaving a mark

[voltron1011]

Originally Posted by agarbati

So Saturn was onto something all along!

Yeah, but have you ever looked at a Saturn door from an angle? All of the plastic panels bulge outward, giving the car an 'unsleek' look. I think BMW's process is probably light years ahead of Saturn's.

[Hej]

Originally Posted by ksfrogman

I was very interested in the use of plastics when Pontiac use them for its Fiero. However, I also recall reading that with repeated thermal heating and cooling, these panels shrunk or warped. I hope plastics technology is much better now than it was then.

Most (all?) of the Fiero bodies were made of fiberglass.

[txusa03]

Originally Posted by agarbati

So Saturn was onto something all along!

Yup, saturn has been using this plastic for years. No dings as they often advertised.

[RichReg]

Originally Posted by Jason

Rich, I was invited to the E92 coupe press event in Germany of course I WISH.

But those were taken at a German E92 press event - pics here - http://www.e90post.com/forums/showthread.php?t=18347

Oh....cool.
Didn't see the pics at that link.
Very impressive technology.......
I guess this means that when there's a 335 Sedan it will also have those type of "plastic" fenders.

[YYdoodle]

Originally Posted by RichReg

Oh....cool.
Didn't see the pics at that link.
Very impressive technology.......
I guess this means that when there's a 335 Sedan it will also have those type of "plastic" fenders.

Hopefully right. Wonder if these plastic fenders also makes any repairs cheaper compared to the traditional metal ones, say when you need to replace the entire fender.

[Hossam]

If this is the case with the fenders, then why not make all the body using the same plastic and save weight and dings effects?

[voltron1011]

Originally Posted by Hossam

If this is the case with the fenders, then why not make all the body using the same plastic and save weight and dings effects?

Probably because the front fenders aren't part of the weight bearing uni-body. The rest of the vehicle's body needs to be made of steel because that is where are the strength is.

[330m]

Plastic panels are more expensive than steel ones.

It's still only saving three kilos on a panel that weighs 10 or more in steel, so the plastic one is quite heavy still.

My Audi A4 had plastic door skins about 4-5 years ago. Great for avoiding dings from other vehicles though.

[F32Fleet]

Sure they reduce weight, but still, they're plastic.

[BMW F22]

how does that differ from the E90? i mean will it affect anything??