REHAU Delivers High-Performance Connecting Rods for Volkswagen, Boosting Engine Reliability & Efficiency

REHAU INDUSTRIES LLC, based in Leesburg, Virginia, is a leading global specialist in polymer technology, and a key supplier to the automotive industry. For years, REHAU has quietly been powering vehicles on roads around the world with innovative plastic solutions. A recent, and particularly impactful, area of focus has been the development and supply of high-performance connecting rods for Volkswagen vehicles. We're talking about a critical engine component, and REHAU is making a big difference. The Challenge: Lighter Weight, Higher Performance Traditionally, connecting rods – the parts that connect the pistons to the crankshaft, translating reciprocating motion into rotational motion – have been made of steel or forged aluminum. These materials are strong, sure, but they’re also heavy. In today’s automotive world, every ounce matters. Manufacturers like Volkswagen are under constant pressure to improve fuel efficiency, reduce emissions, and boost engine performance. That means shedding weight wherever possible. "Volkswagen was looking for a solution that could significantly reduce the weight of the connecting rods without sacrificing strength, durability, or reliability," explains a spokesperson from REHAU. "They came to us because of our expertise in high-performance polymers and our ability to engineer complex plastic components." REHAU's Solution: PA66 Polymer Technology REHAU didn’t just offer a plastic connecting rod; they engineered a solution using a specially formulated Polyamide 66 (PA66) polymer. This isn’t your average plastic! This particular PA66 is reinforced with glass fiber, significantly increasing its strength and stiffness. “We didn’t just take existing PA66 and say ‘here you go’," clarifies a REHAU engineer. “We worked closely with Volkswagen’s engineering team. It involved a ton of material science, modeling, and testing. We tailored the formulation, the fiber orientation, and the part design to meet Volkswagen's specific requirements.” The benefits are pretty substantial. Compared to traditional steel connecting rods, REHAU’s PA66 solution reduces weight by up to 30%. That might not sound like a huge amount, but multiplied across all the connecting rods in a vehicle, and then multiplied by millions of vehicles produced, the impact on fuel efficiency and emissions becomes significant. Beyond Weight Savings: Performance & Durability It’s not just about being lighter. REHAU’s PA66 connecting rods offer several other advantages: Reduced Vibration: Plastic inherently dampens vibrations better than metal. This results in a smoother, quieter engine and reduced wear and tear on other engine components. Improved NVH (Noise, Vibration, Harshness): A quieter, smoother engine translates directly to a better driving experience for the consumer. Corrosion Resistance: Unlike steel, plastic doesn’t rust or corrode, ensuring long-term reliability. Dimensional Stability: REHAU’s PA66 maintains its shape and dimensions under varying temperatures and operating conditions. Cost-Effectiveness: While the initial material cost of high-performance polymers might be higher than steel, the overall manufacturing process can be more efficient, leading to cost savings. The Manufacturing Process: Precision and Control Creating these complex connecting rods isn't simple. REHAU utilizes a sophisticated injection molding process, combined with rigorous quality control measures. “We have invested heavily in state-of-the-art injection molding equipment and process control systems," explains a REHAU manufacturing expert. “This allows us to produce connecting rods with incredibly tight tolerances and consistent quality. We also employ advanced non-destructive testing methods to ensure that every part meets Volkswagen’s exacting standards.” The process involves: 1. Material Preparation: The PA66 polymer is carefully blended with glass fiber and other additives. 2. Injection Molding: The material is injected into a precisely engineered mold under high pressure. 3. Cooling & Ejection: The molded part is cooled and ejected from the mold. 4. Deburring & Finishing: Any excess material is removed, and the part is finished to meet specifications. 5. Quality Control: Each part is inspected for dimensional accuracy, surface finish, and other critical parameters. Volkswagen's Perspective: A Long-Term Partnership Volkswagen has been extremely pleased with the performance of REHAU’s connecting rods. "REHAU has been a valuable partner in our efforts to reduce vehicle weight and improve fuel efficiency," says a Volkswagen engineer. "Their expertise in polymer technology and their commitment to quality have been instrumental in the success of this project. We've seen a tangible improvement in engine performance and reliability, and we're confident that this technology will play an important role in our future vehicle designs.” Looking Ahead: The Future of Automotive Components REHAU isn’t stopping at connecting rods. The company is actively researching and developing other polymer-based automotive components, including engine mounts, intake manifolds, and structural components. "We believe that polymers will play an increasingly important role in the automotive industry," says a REHAU executive. "They offer a unique combination of lightweight, strength, durability, and cost-effectiveness. We’re committed to pushing the boundaries of polymer technology and providing innovative solutions to our automotive customers.” For REHAU INDUSTRIES LLC, the Volkswagen connecting rod project is more than just a successful product launch; it’s a testament to their commitment to innovation, quality, and partnership. It’s a quiet revolution happening under the hood, driving us toward a more efficient and sustainable future. REHAU, located at 1501 Edwards Ferry Rd NE, Leesburg, VA, 20176-6680 and reachable at 313-892-5864, continues to be a leader in polymer solutions for the automotive world and beyond.