German auto giant Volkswagen said it has launched a research and development project that will study the potential for hemp bast fibers in the production of a bio-based substitute for imitation leather that can be used in car interiors, hoping to begin using the material beginning with its 2028 models.
The Wolfsburg-based carmaker said it is working with startup bio-materials maker Revoltech GmbH, Darmstadt, on the surface material, dubbed LOVR – “leather-free, oil-free, vegan and residue-based.” Volkswagen’s Materials Technology, Design, and Components Development departments, and Volkswagen Group Innovation are all involved in the R&D effort, the company said in a press release.
No retooling needed
“Our clear goal is to fuse customer wishes, sustainability requirements and corporate interests,” said Andreas Walingen, Head of Strategy at the Volkswagen, who said the initiative reflects his company’s sustainability goals.
Volkswagen said the material, which can be recycled or composted at the end of its service life, is scalable and can be produced in existing factories. The company said it is using raw material that is a waste byproduct from regional farms where hemp seed is produced for the food industry. In addition to hemp fibers, the covering includes fully bio-based adhesive.
The company wants to get going on actual applications “as swiftly as possible,” according to the release.
Consumers’ thumbs up
The covering could be used as the outermost layer of interior components such as seats, dashboards, door panels, steering wheels, and others. Carmakers select materials for these components based on their aesthetic appeal, durability, comfort, and – increasingly – for their environmental impact.
Imitation leather, now widely used in the auto industry, is made with synthetic materials such as polyurethane, PVC, and microfiber, combined with backing fabrics that are treated – all of which are highly polluting.
The 100% bio material Volkswagen is developing has already received positive feedback from consumers in initial presentations, according to the carmaker.
Demand seen growing
Revoltech has also developed LignoLeaf, a plastics replacement made from lignin, an organic polymer found in the cell walls of plants, especially wood and bark.
Volkswagen is the second-largest automaker in the world – behind Japan’s Toyota – by vehicle sales, with approximately 4.15 million vehicles sold in the first half of this year.
Automotive analysts have said that as carmakers seek greater sustainability, the use of hemp and other bio-based raw materials is likely to grow, driven by the need for lightweight components that reduce emissions and improve fuel efficiency, and increasing consumer demand for eco-friendly products.
Hemp valued for sustainability, light weight in auto manufacturing
Industrial hemp-based raw materials are gaining increasing attention in the automotive industry, particularly for use in composite parts. Hemp fibers are valued for their sustainability and light weight. Here’s an overview of how they are being used and which carmakers are testing them:
Interior panels and trim: Hemp fibers provide high tensile strength and durability, which makes them suitable for producing strong yet lightweight interior components such as door panels, dashboards, headliners, and other interior trim parts. They also offer a natural aesthetic and are often used in combination with natural resins to improve their mechanical properties.
Structural components: Hemp’s ability to blend well with various polymers makes it versatile for a number of exterior applications. When used in composites, hemp bast or “technical” fibers can improve the stiffness and strength of car bodies, bumpers and other structural parts, contributing to better crash performance and overall structural integrity. Hemp fibers are often combined with thermoplastics or bioplastics to create components that are both strong and environmentally friendly.
Insulation and soundproofing: Hemp’s natural fibrous structure makes it an excellent insulator, providing soundproofing and thermal properties in floor mats, insulation panels, and acoustic dampening materials. Its resistant to mold and mildew also makes hemp suitable for automotive interiors.
Seat padding and upholstery: Hemp fibers can be mixed with other natural or synthetic materials to create comfortable and durable seat cushions, backrests, and other upholstered surfaces that are breathable and resistant to wear.
Hemp faces challenges in entering the automobile industry
While industrial hemp holds great promise as a material for automotive applications, suppliers must address several challenges to successfully meet the rigorous demands of the car industry. These challenges primarily revolve around meeting the stringent standards of the automotive industry, ensuring consistent quality, and scaling production. Hemp-based materials can become a viable, sustainable alternative in car manufacturing by overcoming hurdles in:
Quality and consistency of raw materials: Because hemp is a natural material, which means its properties can vary depending on factors like the environment in which it was grown, the harvesting method, and processing techniques. Variability in fiber quality can lead to inconsistencies in the final product’s strength, durability, and appearance, making it difficult to meet uniform standards required by automakers. Suppliers must establish stringent quality control processes, standardize their supply chains, and possibly blend hemp with other materials to ensure consistency.
Processing and manufacturing techniques: Hemp fibers require specialized processing techniques to be used effectively in automotive applications. These processes include decortication, refining, and integration into composites. Traditional manufacturing facilities may not be equipped to handle hemp, requiring significant investment in new equipment or processes. Additionally, achieving the desired mechanical properties in composite materials can be challenging. R&D investment is needed to optimize processing techniques and develop proprietary methods to ensure the fibers meet automotive standards. Collaborations with experienced composite manufacturers can speed up this process.
Compliance with automotive standards and regulations: The automotive industry has very high standards for material performance, safety, and environmental compliance. Hemp-based materials must meet or exceed these standards, which include tests for durability, crashworthiness, flammability, and off-gassing. If hemp-based materials cannot meet these stringent criteria, they will not be adopted, regardless of their environmental benefits. Suppliers must also navigate the complex regulatory landscape in different markets. Extensive testing and certification processes are required to ensure hemp-based materials are compliant. Suppliers need to work closely with automakers to understand and meet these standards.
Supply chain scalability: The demand for hemp-based materials could exceed the current supply chain’s ability to scale, especially if automakers adopt these materials on a larger scale. The cultivation of industrial hemp and its processing into usable fibers is still a developing industry. Inconsistent supply, long lead times, or inability to scale production could deter automakers from committing to hemp-based materials. This could also affect pricing, making hemp less competitive compared to established materials. Developing robust, scalable supply chains is crucial. This involves not only increasing hemp cultivation but also enhancing processing capabilities. Strategic partnerships and investments in supply chain infrastructure will be necessary to meet future demand.
Cost competitiveness: Although hemp is a renewable resource, the cost of producing hemp-based composites can be higher than traditional materials, especially during the early stages of adoption. Automakers are highly cost-sensitive, and any increase in material costs could be a significant barrier to adoption. The cost of transitioning from traditional materials to hemp-based alternatives could also be high for both suppliers and automakers. To be competitive, suppliers need to focus on improving production efficiency, reducing processing costs, and achieving economies of scale. Demonstrating long-term cost savings, such as through weight reduction and improved fuel efficiency, can also help justify the initial investment.
Market acceptance and perception: Despite the sustainability benefits, there may be skepticism about the performance and durability of hemp-based materials among automakers and consumers. If automakers or consumers perceive hemp-based materials as inferior or risky, adoption rates will be low, regardless of the material’s actual benefits. Suppliers need to invest in education and marketing to demonstrate the performance and reliability of hemp-based materials. Success stories and case studies from early adopters can help build credibility.
Integration with existing production lines: Hemp-based composites may require changes in manufacturing processes or equipment, which can be a barrier for automakers who are not willing to disrupt their established production lines. The need for new tooling, training, and potentially reconfiguring production lines can be a significant deterrent, especially if the perceived benefits do not outweigh the costs and risks. Suppliers should aim to develop hemp-based materials that are compatible with existing manufacturing processes. Offering technical support and solutions for seamless integration can also help mitigate this challenge.
Carmakers Testing and Using Hemp-Based Materials
Audi has experimented with hemp-based composites for their vehicles as part of their commitment to sustainability. Hemp fibers are used in interior trim elements to achieve lightweight and eco-friendly solutions.
BMW has been exploring the use of natural fibers, including hemp, in their i3 electric car. The i3’s interior features door panels made from a combination of hemp and other natural fibers, combined with a bio-based plastic.
Ford has been a pioneer in using sustainable materials, including hemp, in their vehicles. The company has tested hemp fibers for use in interior components and has incorporated natural fiber composites into models like the Ford Focus. Henry Ford famously experimented with hemp, soy, flax wheat straw and ramie in a composite material his namesake company developed in the early 1940s.
Mercedes-Benz has integrated natural fibers, including hemp, into various parts of their vehicles. The company uses these materials in interior components to reduce weight and improve sustainability.
Volkswagen is studying the potential for hemp in production of a bio-based substitute for imitation leather that can be used in car interiors, hoping to begin using the material beginning with its 2028 models.
Volvo has explored the use of hemp and other natural fibers in their vehicles, particularly in the development of biocomposites for interior components. Volvo’s sustainability initiatives include reducing the environmental impact of materials used in their cars.
Three Italian companies teamed up in 2021 to make parts that include woven hemp for the M1RA, a touring race car. Engineers on that project said woven hemp could be the basis for a less-expensive alternative to fiberglass.