Outlook 2026: Game-changer materials for e-mobility applications

Mr. Bert Havenith

Director of Strategy, M&A and Marketing Intelligence

Envalior

Website: www.envalior.com

Intensified regulatory requirements and demanding applications are expected to affect the material solutions that are being launched. Around the world, the regulatory landscape is becoming more complex for manufacturers. Examples of forthcoming regulations include the proposed ECHA REACH restriction on PFAS (as well as comparable frameworks in the US and APAC) and the Chinese regulations (GB 29743.2) targeting the electrical conductivity of automotive coolant. Measures like these are requiring manufacturers to rethink the composition of their products, balancing future-focused regulatory preparedness with growing quality and performance demands.

For Envalior, the hydrolysis-stabilized, flame-retardant PBT grade, Pocan® BFN4232ZHR S1, marks a step forward in electrical, mechanical, and safety performance. Building on the inherently low water uptake and excellent electrical insulation properties of PBT, it was designed as an all-around solution for high-voltage applications in e-mobility. In terms of electrical properties, it achieves a CTI value of 600 in all relevant colors, including black and orange. From a mechanical standpoint, it delivers an elongation at break of 2.5%, as well as over 75% property retention after 1,000 hours of hydrolysis in an 85°C/85% relative humidity environment. Finally, with its halogen- and PFAS-free flame retardant package, the new grade conforms to the UL 94 V-0 flammability standard, even at a thickness of 0.75 mm. An additional safety benefit is that the material does not tend to outgas self-igniting volatiles or other substances that are critical from a working hygiene perspective, even at higher injection molding temperatures. Due to its outstanding package of properties, this grade is also well suited for applications beyond e-mobility, such as factories using DC power distribution.

Polytetrafluoroethylene (PTFE) additives have long been used to provide vital anti-wear and lubrication properties to components in high-friction applications. However, increasing regulatory scrutiny of PTFE as a PFAS-classified chemical has prompted some manufacturers to seek PTFE-free alternatives for components such as gears, bearings, timing chains, actuators, and bushings.  With its strong heat-resistance, wear-resistance, and low-friction properties, PTFE-free Stanyl® has been shown to outperform materials like POM, PA66, and PPA (even when they contain PTFE), while offering a pathway to enhanced regulatory compliance. PTFE-free Stanyl® also enables the use of PFAS-free lubricants, further reducing reliance on PFAS.

Envalior’s expanding PTFE-free range, alongside PTFE-containing options, allows manufacturers to future-proof their products while maintaining the highest performance standards in all wear and friction conditions. In the area of mobility, the materials are being applied for high-voltage EV charging connectors (800 V+), inverter mounting frames, e-motor stator insulation, wear/friction components in e-motors/gears. For the Electrical & Electronics (E&E), these are applied in the production of switchgear, connectors, high tracking-resistance electrical components, housing for high-voltage or harsh-environment applications. For consumer goods, these are geared for the production of midsole materials (Arnitel® TPC), as well as durable and lighter-weight consumer components.  Also, the sustainability aspect has not been forgotten as a variety of new recycled- and/or bio-based materials are being made available. Envalior is committed to providing an entire portfolio of bio- and/or recycled-based alternatives by 2030.

We are also seeing many industries go through large-scale transitions, leading to requirements for a new generation of materials that can support more sustainable, durable, and high-performance applications. One trend is the focus on sustainability. Sustainability is a key part of Envalior’s strategy, considering the evolving needs of our existing and future customers for sustainable solutions. Our commitment is to provide an entire portfolio of bio- and/or recycled-based alternatives by 2030. As we move forward, Envalior is set to continuously innovate, exploring and advancing new technologies – from improved mechanical recycling to depolymerization and chemical recycling – to push the boundaries of circularity and sustainability.

We face the same headwinds as other companies: geopolitical uncertainty, tariff disruptions, and protectionist policies. Uncertainty in end markets is causing lower demand, especially in automotive and other plastics-intensive industries. Nevertheless, Envalior’s trading remains robust, and the company has a strong financial position with good liquidity.  In terms of regional presence, China is a high-growth economy and plays a vital role in Envalior’s strategy to expand our customer base. We have invested significantly in expanding production (Jiangyin and Changzhou), as well as R&D and customer support capacity. The recent opening of the Hongqiao Office and Customer Innovation Center in Shanghai, reinforces our commitment to the Chinese market and establishes a core hub for Asia. 

- This article also appears in the International Plastics News for Asia  December 2025 issue. To read the digital version, click here.