Plastic Powers Solar Cars Leading the Solar-Powered Mobility Sector

The 3,000-kilometer journey from Darwin to Adelaide pushed 37 teams from 18 countries to their limits. From scorching heat to dust storms and long stretches of desert, the course tested every aspect of vehicle design. In the qualifying round, Covestro Æthon set the fastest lap among all teams with a time of 1:52.50, securing pole position and a new team benchmark. After five grueling days of outback racing, the car crossed the finish line in fourth place—a performance that placed the students among the global elite.

The integration of innovation and team spirit

What sets it apart is not only the determination of the students but also the choice of materials. Covestro’s Æthon integrates more than a dozen Covestro plastics, more than any previous Sonnenwagen. These advanced materials combine lightweight structures, structural stability, efficient thermal management, and sustainability.

• Seat Recycling and ReuseChemical recycling foam provides seating comfort while reducing resource consumption.
• Elastomer for protection:The quality-balanced Vulkollan absorbs the impact between the battery and the chassis, protecting the structure.
• Using polycarbonate for battery management.The battery holder made of Modclon TC (a thermally conductive polycarbonate) can reduce battery temperature and extend battery life.
• Sustainable CoatingsA room-temperature curing finish with a high proportion of alternative raw materials combines performance with eco-efficiency.
• Other Applications:Covestro plastics are also used in cockpit roofs, car body panels, headlights, seats, and steering wheels—proven reliable even under the extreme climate conditions of Australia.

For Covestro, Sonnenwagen is more than just a racing project. "More sustainable high-performance plastics are key to climate neutrality and circular mobility," said Chief Technology Officer Dr. Thorsten Dreier. Having supported the team since 2017 and served as the main sponsor and technical partner since 2018, the company has used this collaboration as a real-world testing ground. Insights gained in inland areas are directly reflected in the development of materials for future mobility: lightweight structures, improved thermal management, and advanced recycling technologies.

Enter the station, in a remote place.