New Graphene-Enhanced Plastic Set to Revolutionize Auto Parts

A groundbreaking innovation in automotive materials has emerged, as researchers have developed a new substance known as Gratek, which enhances the strength and reduces the weight of glass-filled polypropylene used in auto parts. This new material claims to be 20% stronger and 18% lighter than its conventional counterpart, thanks to the integration of graphene, a material celebrated for its remarkable properties.

What is Gratek and How Does It Work?

Graphene consists of one-atom-thick sheets of carbon atoms arranged in a honeycomb structure, making it the strongest human-made material known. It offers exceptional flexibility, stretchability, and chemical stability, along with high electrical and thermal conductivity. These features make graphene an ideal additive for improving the performance of various materials, including plastics.

Under the guidance of Nello David Sansone, a post-doctoral researcher at the University of Toronto‘s Multifunctional Composites Manufacturing Laboratory, the integration of graphene nanoplatelets into glass-filled polypropylene was rigorously explored. Sansone collaborated with the auto parts manufacturer Axiom Group to develop a proprietary technique that prevents the nanoplatelets from clumping during processing. In previous attempts, clustering led to concentrated mechanical stress, which could ultimately cause material failure.

By ensuring that the graphene nanoplatelets bond specifically to the glass fibers in the polypropylene matrix, Sansone’s method enhances the strength of the fibers while allowing for a reduction in the total number needed. As a result, Gratek achieves its impressive performance metrics while maintaining a graphene content of less than 1%.

Advantages and Market Potential

In addition to its strength and weight benefits, Gratek also offers operational advantages. With a lower glass content, the material generates less wear and tear on the machinery used for cutting and drilling, further enhancing its practicality for manufacturers.

Yet, Gratek does have some limitations. The presence of graphene restricts the color of the material to black. To address this, Sansone has also developed Clatek, a material utilizing clay-based halloysite nanotubes instead of graphene. Clatek reportedly provides similar performance benefits to Gratek but is white in color, allowing for the possibility of dyeing and painting.

Gratek is expected to be contracted by a major automobile manufacturer before the end of 2023, while Clatek is anticipated to be commercially available within two years.

“It has shown real potential to make vehicles lighter, safer, and more sustainable,” said Sansone. He is also working on commercializing another advanced material formulation, named AegisX, through his start-up NanoMorphix. This new venture aims to develop transparent and textile armor for military, defense, aerospace, and personal protection applications.

Sansone’s contributions to material science have been recognized with an award from Mitacs, a Canadian government-funded organization that fosters innovation. Past awardees have developed a range of technologies, including biofuel converters and advanced robotic systems.

The advancements represented by Gratek and Clatek highlight the ongoing evolution of automotive materials, emphasizing the role of innovative research in driving the industry towards greater efficiency and sustainability.