The car industry is undergoing seismic shifts. Powertrains, autonomous driving, and infotainment systems are completely transforming our understanding of mobility. Not to be outdone interior designers and fabric manufactures are making their own innovations - racing to find materials that are sustainable while still retaining an exclusive feel. And in the middle of the Swiss Alps, we think we've found just that.
In the
heart of Fribourg, Switzerland, a quiet revolution was underway. Bcomp, a
company founded in 2011, was developing flax fibres as reinforcement
fabrics that seemed poised to redefine luxury and design sustainably. Initially
making waves in skiing, where their flax fabrics enhanced performance and
provided superior vibration damping, Bcomp's journey took an unexpected turn
when Polestar sought a partnership.
The magic
lay in Bcomp's materials – ampliTex™ and powerRibs™. The former, made from woven flax
fibers, not only reduced vibrations and overall weight but also added a
visually pleasing layer. The latter, inspired by the vein structures of leaves,
formed a 3D structure on panels, drastically increasing strength and stiffness
while reducing weight.
"When
we first saw the material, we knew that this technology perfectly aligns with
Polestar's goals," recalls Ross Kelk, Head of Interiors R&D and
Industrial Program Leader of Polestar's British development team. "Our companies shared the same goals, values,
and a common mindset from the beginning."
Initially,
however, it was not clear how and where the material could be used. And the
visual appearance of the material did not seem to resonate with luxury or
performance in the way that we wanted in our Polestar vehicles. "Together
with the design department we experimented, played, tried different
things," Ross remembers. This experimental approach applied not only to
the material but the entire perception of luxury. "Traditionally,
manufacturers associate luxury with exclusive materials like leather, veneered
wood, and a lot of embellishments. However, we wanted to confidently place the
material in the foreground and openly showcase it. Make sustainability a
tangible, exclusive experience."
“The power
of a designer is to create desire for the right choice, the choice that points
in the right direction,” says Maria Uggla, Head of Colour and Material at
Polestar. “All materials have hidden potential to turn into a luxury expression
and we help reveal them.”
This
approach led to results, as the design team brought about a new aesthetic that
makes this fusion of design, minimalism, and sustainability palpable. “There
are enormous possibilities in exploring and creating new expressions when
working with new sustainable materials,” Maria continues.
The
Polestar Signature Weave, a result of extensive collaboration, was born - a
flexible yet robust material that found its place in the interior seat shells
of the Polestar 3. But it wasn’t straightforward.
A
three-year timeline marked the intensive effort to develop Bcomp into a visible
surface weave within the car's interior. Challenges were abundant – the
material had to perform consistently across extreme conditions; from scorching
heat to freezing cold.
The chosen
weave design was the result of extensive trials and experimentation. A blend of
flex fiber linen textile, natural fiber composite, and powerRibs™, it not only reduced plastic usage but also
contributed to weight reduction. The environmental impact was significant, with
the new hardback made from this material having approximately half the CO2
emissions compared to traditional alternatives.
“There were
many challenges in the development since this is a new way of working for us.
It's one thing to see the woven textile, but a completely different thing to
see the textile processed into a panel. It took many trials but after reviewing
a number of variants, we landed on a specific weave, and it looks awesome. I
can't wait to see it in the car,” Maria says.
The
optimism about the project's potential impact on the automotive industry was
evident. A successful outcome could inspire other OEMs to adopt similar
sustainable materials, setting new standards in sustainable innovation.
"For
us at Polestar it's important that this is the real deal. It is not cosmetic –
it is a sustainable improvement of an interior panel. When we develop new
sustainable material solutions, we make sure to use the materials' properties
full potential." Maria says.
The
Signature Polestar Weave was initially expected to debut in Polestar 5. However, a fast-tracked development process
and positive test prototyping results have allowed us to introduce the material
far earlier than originally expected. But the journey doesn’t end here. Several
new applications are already being tested, performance and sustainability are being
optimized, and the idea of a circular economy is gaining more focus.
"Usually,
creative work is done when a new technology is introduced into the production
process. In our collaboration, it's different: we use insights from the
production process for new creative approaches and ideas. We think in
generations, so to speak," says Ross.
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Source: Polestar.
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