Bcomp’s flax-based materials are transforming interior car parts through back-injection moulding, a standard process in high-volume automotive manufacturing. This method combines flax-fibre materials with thermoplastic layers in a single production step to deliver lightweighting, high performance, and sustainability. With proven large-scale manufacturing compatibility and a unique aesthetic signature, this process unlocks customisable design possibilities for the next generation of vehicles.
Back-injection moulding creates multi-layered components in one production cycle. Materials with different properties are injected into a single mould. This can be done by mechanically bonding layers to a fleece or chemically bonding each layer without adhesives or mechanical fasteners. This ready-to-use solution integrates easily into existing tools and large-scale manufacturing processes, which makes it an ideal entry point for OEMs seeking to enhance their sustainability credentials without disrupting existing production lines.
Bcomp’s materials, ampliTex™ and ampliTex™-PP can all be used as an A-surface layer for back injection or even overmoulding. ampliTex™, Bcomp’s unique flax fibre textile weave, is impregnated with thermoplastic polypropylene (PP). Development work is also underway on new materials created through a mix of natural fibres and sprayed melted PP. The materials are bound together, resulting in finished parts that are both structural and aesthetic, directly out of the tool.
This plug-and-play solution is ideal for automotive manufacturers who want to take their first step towards material sustainability by substituting a percentage of their interior parts for flax , or for those who want to offer consumers a material choice within pre-established manufacturing lines. In most cases, existing tools and equipment such as moulds can be used to expand the material portfolio and refresh the design of current projects. Regardless, back-injection offers advantages in terms of sustainability, process integration and costs, design capabilities and ultimately, part performance; key considerations when evaluating material substitution in the manufacturing sector
Measurable environmental and performance gains
Back-injection of ampliTex-PP cuts plastic content significantly if compared to an equivalent wood deco trim, while delivering weight savings and overall CO2 reduction. Back-injecting PP with natural fibres outperforms traditional plastic or glass fibres: it reduces the mass required per part and provides superior mechanical performance, opening innovation opportunities for lightweighting that align with increasingly stringent environmental regulations and OEM sustainability commitments.
The end-of-life options are also much more circular than other bio-based material manufacturing processes that rely on incineration for energy recovery. PC/ABS, a tough plastic blend often reinforced with glass fibres used in car parts, can be recycled if it stays pure or is effectively separated from other materials. However, this adds extra sorting and processing steps, making recycling more complicated and less efficient. In contrast, single-material designs like back-injected PP are far simpler to recycle. These can be ground directly into small pellets and reused in new products without separating layers or components. This creates a more sustainable lifecycle for automotive components.
ampliTex™ technical fabrics bring inherent advantages beyond sustainability. They meet all mechanical requirements for interior components while delivering lightweight performance compared to standard injection-moulded polypropylene or PC/ABS solutions. UV resistance ensures long-term durability even in sun-exposed interiors, and vibration-damping properties enhance passenger comfort. High radio transparency accommodates the increasing number of sensors and connectivity features in modern vehicles.
Process efficiency that reduces costs at scale
The efficiency gains here matter for high-volume manufacturing. Compared to traditional interior automotive parts made from injected plastic that require additional lacquering, ampliTex™-PP eliminates aesthetic finishing steps, reducing assembly time at scale.
The one-step solution delivers high-end surfaces directly from the tool: aesthetically customisable like compression moulding, but with a faster time to market. By eliminating the need for surface finishing steps or coating, the polypropylene ampliTex™-PP base layer not only costs less than wood and polyurethane alternatives, but also significantly reduces environmental impact. This streamlined process provides both economic savings throughout the production cycle and sustainability advantages, all while maintaining premium aesthetics.
The advantages stack up: reduced assembly time, lower expenses for complex parts, improved aesthetics, and better product integrity compared to assembling separate components. The trade-offs are a higher initial tooling investment and a more complex mould design compared to compression moulding. However, given that back-injection is already one of the most common processes in automotive interior manufacturing, most facilities already have the infrastructure in place or otherwise will find that the investment is paid back quickly.
Design versatility that enables differentiation
The manufacturing process creates finished parts comparable to high-end back-injected wood veneers commonly used in automotive interiors, but provides increased stiffness and a complete new freedom in terms of customisation with patterns and colours. Back-injection grants OEMs access to a wide choice of surface aesthetics, like flax weaves, aluminium or wood to name a few, which are manufactured by the same tool for flexible production. With ampliTex™ brands can now differentiate their design while improving their sustainability credentials.
ampliTex™ delivers a distinct natural look compared to synthetic materials, with customisable fabrics that align with brand identity and mission. This design flexibility extends beyond traditional automotive applications. The precision tolerances achievable with back-injection moulding, measured in fractions of millimetres, make it suitable for consumer electronics, small devices, casings, and panels for electronic devices where precise specifications are critical.
Real-world validation in serial production
In 2023, the Volvo EX30 became the first production vehicle delivered to customers with Bcomp’s composites. ampliTex™ was used in the car’s deco, for the dashboard and door trim, available as an optional feature of the vehicle’s interior. This collaboration demonstrates that premium natural aesthetics can be achieved in high-volume series production without compromising on quality or performance.
The EX30 itself was designed to have the lowest carbon footprint of any model in Volvo Cars’ history. The integration of ampliTex™ into the vehicle’s interior reflects both companies’ shared commitment to sustainability and long-term efforts to reduce lifetime emissions of passenger vehicles, supporting Volvo Cars’ sustainability strategy to sell solely all-electric cars by 2030 and achieve climate neutrality by 2040.
The benefits of the Volvo EX30 model include measurable weight savings, plastic reduction, and simplified production processes with back-injection moulded interior components. While Bcomp’s natural fibre composites are well-proven in demanding motorsport applications like Formula 1 and Formula E, this real-world automotive implementation validates that back-injection moulding of bio-based composites is ready for mainstream manufacturing.
Ready for implementation and scaling
Bcomp’s ampliTex™ materials with back-injection processes are a fundamental shift in how automotive manufacturers can approach sustainable materials. The technology has been validated in large-scale production with Volvo, proving its readiness for series manufacturing. Importantly, the materials can be added as a running change during manufacturing, allowing OEMs to implement sustainable solutions without major production disruptions.
The compatibility with existing compression and back-injection tools means minimal adaptation is required for implementation, reducing both risk and investment. In an industry where regulatory pressures and consumer expectations around sustainability are intensifying, back-injection moulding with natural fibres offers a practical, proven pathway forward. Whether you are a designer exploring new aesthetic possibilities, a production engineer seeking process efficiencies, or a sustainability team working to meet ambitious targets, ampliTex™-PP and innovative natural fibre PPs provide a comprehensive solution that addresses performance, design, and sustainability priorities simultaneously.
Let’s work together to create a world where innovation and sustainability drive the design of automotive interiors.
More information
Learn more about our announcement with Volvo: Click here
