Lightweight construction has now become one of the most sustainable trends in the automotive industry and global demand for polycarbonate (PC) components for roof systems is on the rise according to system supplier Webasto (Stockdorf, Germany).

Dudley-headquartered toolmaker and plastic injection moulder, Petford Tools has secured a £1.5 million investment from Frontier Development Capital that will mean new jobs.

Established in 1971, Petford specialises in the design and manufacture of injection mould tools for the automotive, aerospace, rail, and household sectors. They predominantly support original equipment manufacturers and tier-one automotive manufacturers across the globe, serving household names including Jaguar Land Rover, Bentley and JCB.

Webasto CEO Holger Engelmann is convinced that, "in the future, roof components made of polycarbonate will gain an important share in the largest automobile market in the world." Webasto experts predict that the share of polycarbonate in vehicle roof systems will rise to about 20 percent over the next five years. Polycarbonate has half the density of glass but extremely high impact strength. Elements made of polycarbonate can therefore achieve weight savings of up to 50 percent. The entire roof in this instance weighs approximately 1.2 kg, with length of approximately 98 cm and width of slightly over 1 m at the front.

Due to several new projects, Webasto continues to invest in lightweight construction technology. "We have invested 45 million euros [$61 million] to expand our technology leadership in polycarbonate components for car roof systems even further," says Engelmann. First, a new production hall (about 4500 m²/48,438 ft²) was built at the Schierling site near Regensburg. This facility was then outfitted with three new injection-molding machines and a new paint shop to guarantee that production of polycarbonate components remains state-of-the-art. As a result, these plant extensions assure a production capacity of one million components annually.

Marie Kelly, investment manager at Frontier Development Capital, said: “Following the investment provided in 2013, Petford Tools has continued to thrive, winning more major briefs and working with global brands. FDC’s National Tooling Loan fund aims to help support toolmakers and component manufacturers with the funding needed to complete new and confirmed projects. We are happy to provide Petford Tools with the funding needed to help support them with their newest project, supporting the growth of the company, as well as open further opportunities for Petford Tools in the future with new and existing clients.”

Technically, manufacturing components for roof systems to Class A standard is a highly complex undertaking. To achieve this, Webasto makes the components exclusively at its Plastics Competence Center in Schierling.

FDCs National Tooling Loan Fund is designed to support manufacturing businesses working in England, with available finance of between £50,000 and £2m, to help develop and manufacture tooling for their new and confirmed projects.

Lightweight construction has now become one of the most sustainable trends in the automotive industry and global demand for polycarbonate (PC) components for roof systems is on the rise according to system supplier Webasto (Stockdorf, Germany).

Another factor is that sliding and panorama roofs are very popular in China, topping the specified equipment statistics worldwide. About every third car made in China is delivered with a sliding or panorama roof. The ratio rises to every second car for high-end luxury cars from global OEMs.

The leading roof system supplier is molding PC panels at its plant in Schierling, Germany for supply to China. The PC panel is used at the company's Guangzhou plant to make the panorama roof for the Golf A7. The roofs are then shipped to FAW VW in Foshan and assembled in cars for the Chinese market.

Adrian Lloyd, managing director of Petford, said: “Since our launch in 1971, Petford Tools has grown to become one of the country’s leading mould tool makers and plastic injection moulders. We are at the heart of the UK and global automotive and manufacturing supply chain, with a track record and roster of clients to prove it. This investment from FDC will support us with the manufacture of injection mould tools to support our recently secured contract with Polytec Group. This contract will see us seize more opportunities and build on our history and recent successes.”

This investment from FDC will see Petford Tools in Peartree Lane create 11 new jobs, safeguard 20 existing roles, and welcome a series of apprentices into the business.

The firm has recently secured a major contract with a leading manufacturer, providing products and services to an iconic automotive manufacturer. The investment provided by FDC’s National Tooling Loan Fund will be used to help Petford Tools deliver 41 injection mould tools.

Petford Tools has been provided with investment from FDC previously, as they received a £3.5m investment from the Advanced Manufacturing Supply Chain Initiative (AMSCI) in 2013.

Besides fixed roof elements for the Smart, Webasto also produces panels in Schierling for various car manufacturers. These low-weight panels surround the front and sides of sliding and panorama roofs, producing a high-quality solid glass-like appearance for the entire roof area.