The prize is a juicy one, as the global market for automotive glass is estimated to be worth US$5 – 6 billion annually. And if Exatec can perfect a polycarbonate-based solution, auto-makers around the world will beat a path to its door.

Speaking to AutoAsia seven months after the company was formed, Exatec president Douglas Nutter outlined some potential benefits of the new technology. “In an average sedan, the weight saving could be about 30 – 40%, or about 20kg.” That’s a massive differential and would make a major contribution to fuel-efficiency and, therefore, lower emissions. “Another major advantage we see over glass is that a polycarbonate would be much easier to mould and shape, opening up new possibilities for designers. Also, we believe, poly-carbonate windows could prove safer than glass. ”Exatec is working with America’s National Highway Transport and Safety Agency, which is seeking ways to reduce injuries to vehicle occupants in case of side-impact and roll-over accidents.

Bayer and GE have committed US$40 million to Exatec, which by 2002 will employ 75 full-time staff. Nutter sums up the capabilities that each of these giant companies brings to the table.

"plastics will not
make a dent in the
window market in
the foreseeable future"

“It’s a simplification, but you could describe Bayer as a world class chemicals company and GE as an outstanding engineering and application development company. We’re hiring from both of them, and from a range of other places. After all, we’re a stand-alone company.”

There’s some skepticism about the whole idea within the industry. A panel set up by the Office for the Study of Automotive Transportation at the University of Michigan, composed of 266 members in the auto industry (nearly two-thirds at parts suppliers), forecast that plastics will not make a dent in the window market in the foreseeable future.

Exatec, however, is undaunted. “We have a long way to go and a lot of work to do, but we’re confident we can accomplish our goal of having polycarbonate window systems on high-volume automobiles in seven or eight years.” says Dr. Ralf Dujardin, Exatec vice president of technology.

Step one is to develop and validate the basic technology, based on injection- moulded, hard-coated polycarbonate using silicone coating and glass plasma hard-coat technology and then progress to the to development of poly-carbonate rear screens and rear three-quarter windows.

Once that’s been achieved, Exatec will start work on side windows - a tougher assignment as they have to move and still maintain structural integrity. The company describes the development of polycarbonate windshields as “a long range, third priority”.

When the technology is ready, Exatec will gear up to manufacture more than one million windows per year for customer evaluation. For the auto industry, the huge weight savings offered by plastic glass can’t come soon enough.