In today’s hybrid and internal combustion engine (ICE) vehicles, air management systems face tougher challenges than ever. With growing demand for improved fuel economy and lower emissions, turbocharged engines are becoming more powerful—and hotter. That means air ducts and turbo hoses must withstand higher pressures, aggressive gases, and temperatures reaching 250°C. Traditional rubber and metal parts can handle the heat, but they bring trade-offs: added weight, complex designs, and limited recyclability. The solution? High-performance, blow-moldable thermoplastic copolyesters (TPCs) that combine flexibility, heat resistance, and sustainability.
Turbocharging is key to unlocking fuel efficiency and power in ICE and hybrid vehicles, but boosting engine performance also intensifies thermal and chemical loads on air induction systems. Components like turbocharger hoses, air ducts, and seals must perform reliably under extreme conditions—while also offering flexibility to account for engine movement, space constraints, and complex geometries.
Historically, metal and thermoset rubber have been the go-to materials for these applications. While durable, they tend to be heavier, less design-flexible, and more system complex—often requiring multi-part construction. Moreover, these materials can be non-recyclable or difficult to process sustainably.
To meet modern engine requirements and environmental targets, engineers are turning to next-generation TPCs that deliver high heat resistance and mechanical flexibility in a single-material solution. Envalior’s Arnitel® HT sets a new benchmark in this space, enabling the production of lightweight, flexible, and durable air ducts with fewer components and lower system cost.
Arnitel® HT expands the capabilities of traditional TPCs, offering:
With these attributes, Arnitel® HT enables a simplified, integrated duct design that reduces both cost and environmental impact.
A standout example of Arnitel® HT in action is the hot charge air duct for the Cadillac XT4, developed in collaboration with General Motors, Cikautxo Group, and HENN GmbH & Co KG. The part replaced a thermoset rubber hose and rigid plastic hybrid assembly, cutting weight, improving efficiency, and simplifying installation.
This innovation earned runner-up recognition in the Altair Enlighten Awards in the Enabling Technology category, underscoring the material’s role in reducing mass and complexity in next-gen powertrains.
In blow molded applications requiring even higher continuous-use temperatures, Akulon® Diablo offers an excellent solution. Two grades—HDT2504 BM and HDT2505 BM—deliver robust blow moldability with continuous thermal resistance up to 220°C. These materials are engineered to outperform conventional PA66-based alternatives and offer:
These grades are ideal for advanced ducting systems and can also support wall thickness reduction in select designs, offering even greater mass savings.
As automakers push to meet stricter emissions targets while optimizing engine performance, materials play a critical role in bridging the gap between performance and sustainability. Envalior’s Arnitel and Akulon Diablo materials are designed to meet these evolving needs, enabling lighter, safer, and more efficient air management systems.
By using fewer materials and parts, these solutions also help reduce production complexity, speed up processing, and support circularity in design—helping OEMs and Tier suppliers stay competitive in a changing mobility landscape.
Whether you’re designing high-temperature turbo hoses or looking to cut system complexity, Envalior offers a portfolio of advanced thermoplastics tailored to your toughest challenges.
Contact us to explore how our high-performance materials can elevate your next air management system.
General Technical Service Engineer, Envalior
Russell Bloomfield is a technical service engineer at Envalior. In his current role, he focuses on high performance materials that are used in automotive air induction and powertrain systems. During his career, Russell has served positions in application development, process engineering, as well as market development for high performance polymers. He has a bachelor’s degree in mechanical engineering from the University of Michigan.
26 June 2025
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