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Lightweight plastic components: multifunctional, durable and efficient.

Industry requirements regarding functionality, safety, stability, environmental compatibility, design and comfort are exacting. With its comprehensive expertise in materials, processes and fabrication, ElringKlinger is in a position to meet this challenge. Drawing on many years of experience, we offer lightweight components for drive train and car body.

At ElringKlinger, intelligent lightweight design means:

  • Reduced material use
  • High cost-effectiveness
  • Integration of numerous functions
  • Function test of complete module
  • Improved NVH characteristics
  • Design freedom
  • Shorter development times
  • Safe, simple assembly
  • Recycling capability

Lightweight design expertise for the drive train from ElringKlinger

The first lightweight plastic component went into serial production at ElringKlinger at the end of the 1990s. Today, we are producing around 10 million units a year ­– and this volume is set to grow.


Our products for the drive train:  


Cam covers for cars and commercial vehicles

Cam covers for cars and commercial vehicles

We have optimized the weight of our plastic cam covers, reducing the wall thickness of some components to less than 2 mm. The sealing technology and fixing components developed in-house by ElringKlinger are key elements of the overall module. Another important feature is the crankcase ventilation with pressure control and high-performance oil separators.

As the temperatures in the engine compartment are constantly increasing, the cam cover has to be especially heat-resistant. Our modules are well equipped to cope with this environment thanks to integrated thermal and acoustic shielding systems.

For the commercial vehicle segment we integrate a charge air manifold into the cam cover module and can thus offer customized lightweight solutions. For example, as well as a high-performance oil separator, the module can also incorporate other functions like pressure control valves and oil filler caps.

Oil separation modules and systems

Oil separation modules and systems

ElringKlinger has developed a range of oil separation modules and systems. Detailed information is provided in our brochure “Lightweight plastic components. For cars and commercial vehicles.”

Cam frames

Cam frames

Apart from the increasing use of light polyamide cam covers, the commercial vehicle segment is also embracing another trend: installing a plastic cam frame with integrated cable assembly between cylinder head or aluminum camshaft frame and cam cover. ElringKlinger can offer the best possible solution for your requirements.

Charge air ducts and intake air manifolds

Charge air ducts and intake air manifolds

ElringKlinger is also doing pioneering work in the area of plastic intake systems and charge air ducts and offers product solutions in materials with higher temperature resistance (200°C, for brief periods as much as 220°C). These include charge air manifolds and ducts with EGR feed point. Increasingly, we are also applying the design and process technologies developed to meet the stringent requirements in the commercial vehicle sector to the car and small engine segment.

Resonators/EGR mixers

Resonators/EGR mixers

Resonators are often used in modern engines to counteract the noise from turbochargers and piping. They can be positioned at various points along the charge air section. Due to the high temperatures (up to 220°C) that can occur in these areas and the pulsating charge pressures (up to around 3 bar), the plastic resonators have to meet exacting requirements.

When designing EGR mixers, ElringKlinger makes use of CFD simulation techniques to calculate and if necessary optimize the mixing behavior of EGR gas with fresh air and the pressure loss in the system. To reduce installation space and weight, a combination of resonator and EGR mixer in one component is also conceivable.

Oil pans

Oil pans

With the development of Euro 6- and EPA 10-compliant engines, polyamide oil pans have also become established in the commercial vehicle sector. Nowadays, almost every new oil pan developed worldwide is made of polyamide. ElringKlinger is a global market leader in this segment with the capacity to produce these components on 3,000-ton injection molding machines in Germany, China and the NAFTA region.

The reasons for the resounding success of polyamide are manifold and include primarily the enormous weight and costs savings but also the acoustic benefits. Polyamide oil pans from ElringKlinger meet the full range of conditions, including safety requirements.

Oil intake modules

Oil intake modules

Oil intake modules – some featuring integrated oil return check valves, high pressure lines and filter strainers, are used in both cars and commercial vehicles. Here too, weight and cost savings of up to 50 percent are possible compared with metal and hybrid solutions, while the components also offer better functionality. ElringKlinger products, especially its welded components, feature superlative burst pressure resistance and therefore offer superior resistance to internal pressure pulsations at up to 150°C over their entire service life.

Oil tanks

Oil tanks

Oil tanks developed by ElringKlinger can be installed on the side of the crankcase or at various points in the engine compartment, making for easier oil and filter changes during servicing. Numerous extra functions can be integrated: crankcase ventilation, including oil separation, screwed-in oil pressure sensor, oil drain plug, holder and connecting hole with dipstick, oil filter with integrated oil drain for drip-free oil filter changes and detached fastening on vehicle structure.

Engine front and rear covers

Engine front and rear covers

Apart from areas like cam cover, (charge) air conducting components and oil pans, where plastics predominate, plastic housing parts are increasingly popular for the engine front and rear. ElringKlinger has already successfully implemented relevant projects for both cars and commercial vehicles.

Transmission modules

Transmission modules

As well as in the engine area, plastic is increasingly also being used in the meantime for components in and around the transmission system. This includes, for example, the transmission oil pan modules offered by ElringKlinger for automatic gearboxes.