Over the past five years, Autoneum experts in Sales, Research & Technology, Development Centers and Program Management have worked closely with Polestar R&D teams to develop a suite of Autoneum components manufactured entirely from 100% polyester, setting new standards for environmental performance and driving comfort in the premium electric segment.

Unlike traditional multi-material automotive components, Autoneum’s monomaterial polyester solutions are fully recyclable, lightweight and produced with minimal energy and water consumption. Their high content of recycled polyester and latex-free, low-waste manufacturing process significantly reduces CO₂ emissions across the component’s lifecycle. In electric vehicles, these components also enable easier end-of-life recycling and battery access, supporting circularity and contributing to Polestar’s mission towards a truly climate-neutral car.

A journey of innovation and collaboration

This robust partnership has paved the way for several new Autoneum innovations specifically tailored for the Polestar 5. The Ultra-Silent Frunk & Frunk Tray with PET knit fabric is a front trunk for electric vehicles that combines lightweight construction with an outstanding acoustic performance. The Ultra-XStream Diffuser is an advanced underbody component that was developed to deal with extreme aerodynamic loads while ensuring a superior acoustic performance. The Ultra-Silent Hush Panels, mounted under the interior cockpit, deliver both noise reduction and design flexibility. The polyester felt Outer Dashes are lightweight, high-performance components for superior noise and thermal insulation.

“Developing these components has been a true journey of innovation and collaboration with Polestar,” said Kevin Van Gorp, Technical Expert, Autoneum. “We were able to provide the customer with expertise from across Autoneum’s global footprint, from our early work at the Polestar engineering center in England to the production ramp-up. The result is a portfolio of parts that not only deliver on acoustic and thermal performance but also set new benchmarks for sustainability.”

Solutions that are shaping the future of mobility

Marria Uggla, Head of Color, Material and Finish Design at Polestar, says: “Driving an electric car is a significant step toward a more sustainable future, but we must also consider the entire production process to achieve a truly sustainable journey. Our vehicles are a product of Scandinavian innovation, and our design philosophy is rooted in pure minimalism.”

This focus on holistic sustainability and design excellence is reflected in Polestar’s broader vision for the future of electric vehicles. “As a modern premium EV brand, our goal is to redefine luxury by designing sustainable, minimalist materials with innovative aesthetics,” says Marria Uggla. “We believe in the power of design to encourage consumers to make more sustainable choices.

Alongside the sustainable innovations making their debut in Polestar 5, Autoneum will provide additional components for this luxury grand tourer, underscoring the strength of the partnership between the two companies that have worked together on prior Polestar models.

With the current project, Autoneum reaffirms its commitment to delivering high-performance solutions that are shaping the future of mobility. The company’s pioneering use of 100% polyester materials not only reduces the environmental impact but also enhances acoustic comfort and driving pleasure.

Facilitate the shift toward the circular economy

Autoneum’s recyclable components for Polestar 5 are engineered to enable straightforward end-of-life recycling and reuse. By utilizing monomaterial solutions, Autoneum ensures that these parts not only minimize the environmental impact during production but also facilitate resource recovery, further advancing the shift toward the circular economy and sustainable automotive manufacturing.

“Our partnership with Polestar is a testament to what can be achieved when sustainability, technology and passenger comfort are placed at the heart of innovation,” said Pascaline Brégeon, Head of Strategy & Sustainability, Autoneum. “By working closely with the customer’s engineering teams, we have accelerated the adoption of sustainable products that meet the highest standards for performance.”