Ambitious Development Partnership

Rehau Produces Bumpers For The New Audi Tt

Rehau/Győr, (PresseBox) - At the beginning of the Motor Show in Paris, the new Audi TT was elected "Innovation of the Year" at the beginning of October. Apart from the many new technical features, the reason was mainly the appealing design solutions for the next generation of the popular sports car model. The four brand rings placed in the center of the hood for the first time and an extremely broad single-frame grille give the new Audi TT its distinctive profile. For the bumper package, the automobile manufacturer got REHAU on board again. The development partner with its headquarters in the German town of Rehau in the Upper Franconia District produces the components for the front and the rear section of the sports car at its Hungarian location of Györ.

Officially inaugurated in October 2013, the REHAU plant in the Hungarian town of Györ has become a constant factor in the international manufacturing network of the automotive parts supplier REHAU since. A staff of about 280 employees is working here. Apart from the bumpers for the Audi A3 cabriolet and the Audi A3 sedan, the new Audi TT models have been running off the belt in Györ since 2014. And that applies for all variants: the basic line, the S line package and the TTS model. The rocker panels for the sports car are produced in Györ as well. The painted component part, i.e. a rocker panel with contrasting edges, will characterise the appearance of the new Audi TT in every model as well, and - similar to the broad wheel arch - will be reminiscent of the first TT generation.

For the current third generation, the supplier developed the details of a completely new front line view in close co-operation with the car manufacturer in Germany: "The design specifications of the customer - an extremely large-format bumper fascia in horizontal direction with a very broad, and yet filigree high-gloss varnish radiator grille - were the high optical requirements," says Dr Manfred Rudlof, the responsible project manager at the polymer specialist. "On the one hand, the bumper has to have a high degree of stability and on the other hand it has to integrate the other component parts, such as mudguard or radiator grille, almost seamlessly right down to the smallest detail," reveals the expert. The construction of the bumper has been a "thrilling" task primarily due to the fact that the diamond shape "warps" around the single-frame grille almost perfectly. This special shape has had clear implications for the tools and the tool layout, continues Dr Rudolf to say. The two-fluted construction of the rear bumper has been created in an upmarket fashion as well.

However, Erik Flach, the responsible development engineer of the TT project at REHAU, would not go so far as to say that the demands on the construction of component parts used in sports car models are higher than for other types of vehicles in general. "Naturally, sports car models exude a certain fascination at all times," admits the 35-year-old engineer. "Personally I am fascinated more by being involved in the development of a vehicle because the moment of enjoyment comes, when the car drives past on the road and you know that our know-how is behind it all." All-in-all a team of fifteen at the location of Rehau was active developing the new TT together with Audi. Together with the colleagues at the Hungarian location of Györ, they accomplished a masterly performance during the last few months.

For energy-efficient construction, the use of renewable energies and water management as well as mobility and future living, REHAU makes sustainable contributions to the ecological and economic challenges of tomorrow. Competence and innovation have made the company a leading system and service provider of polymer-based solutions in the areas of construction, automotive and industry. Passion for the fascinating, unlimited potential uses of polymer materials is a basic requirement for REHAU in order to be successful worldwide as a leading premium brand. More than 18,000 employees all over the world achieve growth and success for REHAU at over 170 locations.

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