Balancing performance and fuel economy with robust air intake systems

Hybrid cars, which incorporate an internal combustion engine (ICE) alongside a battery, continue to play an important role in cutting global carbon emissions. OEMs look to optimize the sustainability of hybrid vehicles by fitting them with compact turbocharged engines that are designed to balance performance and fuel economy. To lightweight engines and improve vehicle sustainability, manufacturers have replaced metal and rubber materials for these parts with polyamide 66 (PA66). Yet, this polyamide provides limited thermal resistance and can create supply chain risks.

Although battery electric and hydrogen vehicle adoption is accelerating rapidly, hybrid cars that use fuel-efficient ICE are critical to meeting greenhouse gas emissions targets. Rising government subsidies and new technologies are projected to drive the global hybrid vehicle market at a compound annual growth rate of 29% over the next 5 years.

Yet, compared to naturally aspirated engines, hybrid powertrains generate higher operating pressure and temperatures up to 220°C. PA66 that uses traditional heat stabilization technology has served the needs of lower pressure, naturally aspirated engines for decades. However, these materials often don’t meet the higher temperature and pressure demands posed by turbocharged engines.

Hybrid powertrains also offer less packaging space. As a result, materials that can be suction blow-molded offer the highest level of design flexibility. This enables the last-minute incorporation of a duct design into an already crowded engine compartment.

Envalior’s newly commercialized Akulon Diablo HDT2504 BM and HDT2505 BM materials deliver outstanding pressure and temperature resistance and are customized for the suction blow molding process.

We offer a complete range of high-performance material solutions for air intake system parts approved for various blow and injection-molding processes. With our track record of declaring zero force majeures during the COVID-19 pandemic, we enable you to leverage the materials best suited to your changing needs, and ensure you have reliable access to them as business demand evolves.



Diablo HDT2500

Diablo HDT2504BM
Stanyl® Diablo



Clean air ducts   X   X     
Resonators     X    X   X 
Hot charge ducts   X   X   X   X   X   X 
CAC end caps     X    X   X 
Cold charge ducts   X   X     
Air intake manifolds     X    X  
Engine covers           X
Air filters           X

Providing you with a best-in-class PA66

Many of our customers have come to rely on PA66 when developing a variety of parts for air intake systems. Akulon Diablo PA66 responds to the growing demand for thin, compact auto parts built to withstand high thermal stress under the hood. The “at temperature” strength of our blow moldable Akulon Diablo grades can reduce wall thickness by as much as 50% compared to the next best alternative – enabling both cost and mass reduction.

Optimized for your most demanding applications

Stanyl Diablo PA46 provides superior thermal and creep resistance. Compared to PA66, the material offers a peak operating temperature that’s 20°C higher, enables wall thickness reductions up to 10%, and achieves 30% higher stiffness after heat aging at 200°C.

Our Xytron PPS solution provides a lightweight alterative to steel in exhaust gas recirculation (EGR) components that require enhanced chemical resistance. The material significantly outperforms competing polyphthalamides (PPA) after prolonged aging in high-heat acidic mixtures.

Helping you enhance vehicle sustainability

Arnitel HT is optimized for hot charge duct applications with an operating temperature well above competing thermoplastic copolyesters (TPC). Compared to traditional rubber solutions, the 100% recyclable material enables weight savings up to 40% and cost savings up to 20%. Our heat-stabilized EcoPaXX solutions, which are well-suited for engine cover and air filter applications, further improve vehicle sustainability with their bio-based content and ultra-low carbon footprint.

In addition to providing you with the best material solutions, we offer comprehensive consultation services to help you meet precise design specifications and elevate system performance. With our 30-year track record of helping auto-parts suppliers succeed, we’re ready to support you through every step of delivering air intake system parts that keep pace with OEM’s shifting requirements.

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Published on

16 December 2022


  • Blog (185)
  • Automotive (58)
  • Thermal Management (13)


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Russell Bloomfield

General Technical Service Engineer

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.

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