Plastic Trends in Automotive and Vehicle Technologies: Innovative Solutions from Safari Plast

The automotive sector is evolving quickly. Electrification, smart systems and sustainability goals are reshaping vehicle technologies, and lightweight, durable plastics are at the heart of this change. The expansion of thermoforming is opening new opportunities for high‑performance plastic sheets in car, caravan and commercial‑vehicle design. Safari Plast leads this transformation by specializing in thermoform‑compatible plastic sheets within the automotive and vehicle technologies segment.

Thermoforming and Plastic Trends in Automotive

As we move into 2025, the thermoforming industry is experiencing notable growth. Technological advances and wider applications mean that sectors such as automotive and medical are turning to thermoforming to produce lightweight, durable part. Because thermoforming can deliver precision and customisation, it supports energy efficiency, cost savings and sustainability. The increasing use of lightweight and recyclable materials like polypropylene and high‑molecular‑weight polyethylene further fuels market expansion.

Electric vehicle sales reached 17.6 million units in 2024 and are expected to approach 22 million in 2025. This surge relies not just on battery and power‑electronics improvements but also on high‑performance polymers that enable lightweighting, thermal management, electrical insulation and structural integration. Reducing a vehicle’s mass by 10 % can improve energy efficiency by up to 8 %, so materials like PP, PA and glass‑fibre‑reinforced polymers are widely used for underbody shields, dashboards and exterior panels.

Safari Plast’s High‑Performance Sheet Solutions

Safari Plast manufactures high‑performance plastic sheets for interior and exterior automotive parts. These sheets are lightweight, durable and aesthetically pleasing while remaining easy to process; they are used in cars, campervans, commercial vehicles, buses, rail systems and light transport vehicles.

The company follows a thermoforming‑compatible production philosophy, developing multi‑layer co‑extruded sheets with six different surface textures and options for matte, gloss and metallic finishes.

Application‑Oriented Material Development

• Exterior trim applications: class‑A UV‑resistant surfaces combined with impact‑absorbing sublayers for roof modules and lightweight outer doors.
• Interior trim applications: high scratch‑resistant textures, soft‑touch surfaces and decorative panels for refined cabin designs.
• Customer‑focused approach: automotive‑compliant product development and quality control, customised packaging and logistics, short lead times, flexible scheduling and technical support.
• Sustainable manufacturing: Safari Plast recycles all internal production waste, employs energy‑efficient production systems and integrates recycled raw materials into its products.

Solutions for 4x4 and Off‑Road Vehicles

Off‑road and pickup vehicles need to withstand extreme conditions. Safari Plast offers plastic sheet solutions that provide high impact resistance, UV durability, scratch resistance and low weight. These materials are used in fender flares, bed liners, side body panels, interior floor mats, hood and engine protection covers and tailgate panels. Engineering plastics such as ABS, HDPE and ABS/PMMA are produced in six different surface textures with matte, gloss or metallic effects. Sheets are thermoformed to fit each vehicle model precisely, with customised options for colour, thickness and surface finish.

Electromobility and Lightweight Construction Technologies

Lightweight construction solutions reduce vehicle mass while improving fuel efficiency, load capacity and energy performance—features that are critical for electric vehicles and micro‑mobility systems. Safari Plast supports this transition by providing thermoformable sheet solutions for electromobility applications. These sheets enable the production of lightweight body panels, roof modules, interior consoles and compact body parts. Compared with conventional materials, lightweight plastics extend range and lower carbon footprint. The thermoforming process, with its low mould costs and fast time‑to‑market, is a strategic solution for low‑ and medium‑volume production runs.

Commercial Vehicles, Buses and Rail Systems

Components used in heavy‑duty vehicles must withstand mechanical impacts, heat, vibration and environmental conditions while meeting high standards of aesthetics and functionality. Safari Plast supplies multi‑layer thermoformable sheets with superior impact resistance, heat‑deformation strength and flame‑retardant properties where required. Application areas include bus ceilings and side panels, rail seat backs and partition covers, commercial‑vehicle door trims and control panels, tractor cabin panels and wind deflectors. These advanced plastic sheets offer significant weight and processing advantages over traditional SMC materials, delivering high performance at lower cost for large surface exterior parts and rigid structural components.

Caravan and Motorhome Industry

Caravan and motorhome manufacturers need materials that are lightweight, durable and easy to process. Safari Plast develops sheets that combine aesthetics, lightweight design and durability for both interior and exterior applications. The sheets are thermoforming compatible and available in a wide range of thicknesses, colours and surface finishes. Applications include side panels, roof panels, dashboards, gas‑box covers, bumpers, foldable bed panels, shower trays and lighting frames. Material advantages include lightweight construction for improved fuel efficiency, high impact and deformation resistance, UV and temperature stability and six distinct surface textures.

Special‑Purpose and Low‑Volume Vehicles

Safari Plast plays a key role in projects involving special‑purpose vehicles and low production volumes. Thermoforming provides design freedom, low mould costs and superior surface quality, making it ideal for lightweight platforms, micro cars and innovative mobility projects. These sheets deliver class‑A surface quality without the need for secondary painting. Even for production runs between 1,000 and 30,000 units, thermoforming offers cost and speed advantages. Materials such as ABS, ABS/PMMA and ABS/PC blends provide excellent UV, impact and heat resistance, along with uniform colour transitions.

Sustainability and Recycling

The environmental impact of plastics is a common concern, but modern manufacturing and recycling techniques can mitigate it. Safari Plast places sustainability at the centre of its operations by recycling 100 % of internal production waste, using energy‑efficient systems and integrating recycled materials into its products. Industry‑wide, innovations such as improved heating systems, optimised machinery and streamlined workflows reduce energy consumption and waste.

In the EV market, some automakers now require up to 25 % recycled materials in plastic components. Such requirements highlight the growing emphasis on circularity and the need to balance performance with recyclability. Safari Plast’s integration of recycled raw materials aligns with these global trends and supports cleaner, more sustainable transportation.

Conclusion

Plastic materials are becoming increasingly important in automotive and vehicle technologies. Thermoforming and engineering plastics enable vehicles to be lighter, stronger, more aesthetic and more sustainable. The rise of electric vehicles, the off‑road segment, commercial vehicles, caravans and special‑purpose vehicles all require tailored solutions. Safari Plast meets these needs with high‑performance plastic sheets, offering customer‑specific designs, rapid production and a commitment to environmental responsibility. If you’re looking for lightweight, durable and attractive solutions for your automotive projects, Safari Plast’s expertise can help you shape the future of mobility.