REHAU Powers Volkswagen with High-Performance Connecting Rods: A Virginia-Made Solution for Engine Reliability

Leesburg, VA – November 8, 2023 – REHAU INDUSTRIES LLC, a leading global specialist in polymer technology headquartered in Leesburg, Virginia, is quietly playing a crucial role in the performance and reliability of Volkswagen vehicles worldwide. While many recognize REHAU for its work in windows, construction, and furniture, a significant and increasingly important part of their business focuses on high-precision automotive components, specifically Volkswagen connecting rods. For those not in the automotive tech world, connecting rods are vital. They're the link between the piston and the crankshaft inside your engine. They take the force from the combustion and turn it into the rotational power that drives your car. A bad connecting rod? That's a major engine problem – think expensive repairs and a car that's not going anywhere. REHAU’s contribution isn't just about making parts. It's about making them better. They’ve spent years perfecting a process using advanced polymer materials – specifically polyamide – to create connecting rods that are lighter, stronger, and more durable than traditional metal versions. “We’re not just a plastics company anymore,” explains a REHAU spokesperson. “We’re a materials science company. We engineer solutions for really tough challenges, and in automotive, that means pushing the boundaries of what’s possible with polymers.” Why Polymers for Connecting Rods? It’s About Performance & Efficiency. You might be thinking, “Plastic in an engine? Seriously?” It sounds counterintuitive. But here's the deal: these aren't just any plastics. REHAU uses highly engineered polyamides, which are incredibly strong, heat-resistant, and have excellent fatigue properties. Here's a breakdown of the benefits: Weight Reduction: Polymer connecting rods are significantly lighter than their forged steel counterparts. This weight reduction directly translates into improved fuel efficiency and reduced emissions. Every pound shaved off rotating engine components makes a difference. Reduced Friction: Polymers have inherently lower friction coefficients than metal. This means less energy is lost to friction within the engine, further boosting efficiency and performance. Improved NVH (Noise, Vibration, and Harshness): Polymers dampen vibrations more effectively than metal. This results in a quieter and smoother driving experience. Cost Optimization: While the initial material cost might be comparable, the manufacturing process for polymer connecting rods can be more streamlined, leading to overall cost savings. Design Freedom: Polymers allow for more complex geometries and integrated features, opening up possibilities for optimized engine design. REHAU’s Process: Precision Engineering & Quality Control REHAU doesn’t just mold plastic. They’ve developed a highly specialized process, built around precision injection molding and rigorous quality control. This includes: Material Selection: Choosing the right polyamide grade is critical. REHAU works closely with material suppliers to ensure consistency and performance. They're not just buying plastic; they're specifying a material with a precise set of characteristics. Mold Design: The molds used to create the connecting rods are incredibly complex and require extreme precision. REHAU's engineers use advanced simulation tools to optimize the mold design for flow, cooling, and part quality. Injection Molding: The injection molding process is carefully controlled to ensure consistent part dimensions, density, and mechanical properties. This involves precise control of temperature, pressure, and injection speed. Automated Inspection: Every connecting rod undergoes rigorous inspection using automated optical systems and other non-destructive testing methods. This ensures that every part meets Volkswagen’s strict quality standards. Statistical Process Control (SPC): REHAU uses SPC to monitor the manufacturing process in real-time and identify any potential issues before they lead to defects. Volkswagen’s Confidence in REHAU Volkswagen has been a long-standing partner of REHAU, and the decision to adopt polymer connecting rods was a significant one. It's a testament to REHAU’s ability to deliver consistent quality, reliability, and performance. “Volkswagen is committed to innovation and sustainability,” says a source familiar with the project. “REHAU’s polymer connecting rods help us achieve both of those goals. They’re a key component in our efforts to build more efficient and environmentally friendly vehicles.” The specific Volkswagen models utilizing REHAU’s polymer connecting rods are not publicly disclosed, but sources indicate they are increasingly being used in a range of engine platforms. Made in America, Driving Global Innovation While REHAU is a global company with operations around the world, the production of these critical Volkswagen components takes place right here in Leesburg, Virginia. This represents a significant investment in American manufacturing and creates skilled jobs in the local community. "We're proud to be a part of the American manufacturing landscape," says the REHAU spokesperson. "We believe that by investing in advanced technologies and skilled workers, we can continue to innovate and deliver high-quality products to our customers around the world." Looking Ahead REHAU is continuously researching and developing new polymer materials and manufacturing processes. They are exploring the use of reinforced polymers, carbon fiber composites, and other advanced materials to further improve the performance and durability of automotive components. The future of automotive engineering is likely to see even greater use of polymers, and REHAU is well-positioned to be a leader in this transformation. They’re not just making parts; they’re shaping the future of mobility. Contact: REHAU INDUSTRIES LLC 1501 EDWARDS FERRY RD NE LEESBURG, VA 20176-6680 313-892-5864