New Graphene-Reinforced Plastic Makes Automotive Parts 20% Stronger and 18% Lighter

Written by Fabio Lucas Carvalho

Published on 19/11/2025 at 16:30

Novo plástico com grafeno aumenta resistência em 20% e reduz peso em 18%, oferecendo alternativa mais leve e eficiente para peças automotivas

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Material Created by Researcher at the University of Toronto Combines Graphene and Glass Fiber Reinforced Polypropylene, Increasing Strength and Reducing Weight of Automotive Parts, While a Second White Version Promises Broader Applications in the Industry

Glass fiber reinforced polypropylene is widely used in the manufacturing of automotive parts, but researchers have found ways to further enhance its performance. Enter Gratek, a material that promises to increase strength by 20% and reduce weight by 18%, thanks to the inclusion of graphene in its composition.

Graphene is made up of extremely thin sheets of carbon atoms arranged in a hexagonal pattern.

It is considered the strongest man-made material known, as well as being flexible, extensible, and stable. Additionally, it also boasts high electrical and thermal conductivity.

ARTICLE CONTINUES BELOW

How the Technology Was Created

Postdoctoral researcher Nello David Sansone, a member of the Multifunctional Composite Manufacturing Laboratory at the University of Toronto, investigated methods to add graphene nanoplatelets to glass fiber reinforced polypropylene glass.

The initiative took place while he was working at the auto parts manufacturer Axiom Group, in collaboration with the university.

Previous attempts to incorporate graphene into automotive parts faced challenges. The material tended to clump during processing, which concentrated mechanical stress in unsuitable points and led to the risk of failures.

The Solution Found

Sansone overcame the issue by developing a patented technique that allows the nanoplatelets to bond only to the glass fibers within the plastic matrix.

This behavior prevents clumping. As graphene strengthens the fibers, there is a reduced need for the amount of glass. Thus, Gratek outperforms regular polypropylene reinforced with glass fiber in strength and lightweightness.

The new composite contains less than 1% graphene. Furthermore, the reduced volume of glass decreases wear on the machines used for cutting and drilling, providing an additional advantage to the manufacturing process.

New Possibilities and Limitations

One point that limits Gratek is its color. Due to the graphene, the material can only be produced in black. To meet broader demands, Sansone created another material: Clatek. It utilizes clay-based halloysite nanotubes in place of graphene. The solution offers similar performance but features a white color and can be dyed or painted.

There is hope that Gratek will be adopted by a major automaker this year. Clatek is expected to hit the market within two years, expanding the range of options for vehicle manufacturers.

Outlook and Recognition

Sansone states that the advancements demonstrate great potential to make cars lighter, safer, and more sustainable.

He is also working on the commercialization of AegisX, formulated by his startup NanoMorphix, aimed at transparent and textile shielding for military, aerospace, defense, and personal protection sectors.

The researcher recently received an award from Mitacs, an organization funded by the Canadian government dedicated to promoting innovation.

Among those recognized in previous years are initiatives such as a towable converter that transforms agricultural waste into biofuel, a vision-based flight recorder, an augmented reality feedback system for athletes, and an amphibious robot powered by a screw.

New Graphene-Reinforced Plastic Makes Automotive Parts 20% Stronger and 18% Lighter

Material Created by Researcher at the University of Toronto Combines Graphene and Glass Fiber Reinforced Polypropylene, Increasing Strength and Reducing Weight of Automotive Parts, While a Second White Version Promises Broader Applications in the Industry

How the Technology Was Created

The Solution Found

New Possibilities and Limitations

Outlook and Recognition

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New Graphene-Reinforced Plastic Makes Automotive Parts 20% Stronger and 18% Lighter

Material Created by Researcher at the University of Toronto Combines Graphene and Glass Fiber Reinforced Polypropylene, Increasing Strength and Reducing Weight of Automotive Parts, While a Second White Version Promises Broader Applications in the Industry

How the Technology Was Created

The Solution Found

New Possibilities and Limitations

Outlook and Recognition

The Soviet Union spent 22 years drilling into the Earth’s crust and reached a depth of 12,262 meters — they found water where it was thought impossible, hydrogen bubbling from the rock, granite that is 2.7 billion years old, and temperatures of 180 degrees that melted the drill bits.

Egypt wants to draw 10 million cubic meters of water from the Nile per day into the desert, irrigate a new agricultural frontier, and build a city where there is currently only sand.

BRICS is preparing a payment system inspired by the Brazilian PIX that will allow direct transactions between countries using national digital currencies without relying on the dollar or Western banks as intermediaries.

Ethiopia has banned gasoline and diesel cars, placed over a hundred silent electric buses on the streets of Addis Ababa, and now aims for half a million electric vehicles by 2030, all powered by Africa’s largest dam and a courage that few countries have shown.

Stored for over 100 years, the first underwater tunnel in Latin America receives a decisive boost with a loan of R$ 2.5 billion signed in April and promises to connect Santos and Guarujá, on the coast of São Paulo, in just 5 minutes.

A brand that has been manufacturing motorcycles since 1901 launches its first electric model, and the price shocked the world: $3,000, weighing only 124 kg and accelerating from 0 to 60 km/h in 3.7 seconds…

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