Top 5 Automotive Applications of PP Bubble Board You Should Know
As the automotive industry continues to evolve toward lightweight, energy-efficient, and sustainable design, more and more manufacturers are turning to advanced plastic materials to replace traditional components. One such material is PP Bubble Board, a lightweight, rigid, and recyclable polypropylene-based board with a unique three-layer structure.
At Polyreflex, we specialize in producing high-quality PP Bubble Boards for various industrial applications. With over 18 years of manufacturing experience, we've seen firsthand how PP Bubble Board is becoming a go-to solution in automotive design and engineering.
Here are the top five automotive applications where PP Bubble Board is making a significant impact.
1. Trunk Floor Panels
PP Bubble Board is widely used as the base panel for car trunk floors, where strength, weight, and durability matter most.
Why It's Used
The board provides a sturdy yet lightweight surface that can withstand heavy luggage, equipment, and day-to-day wear and tear.
Key Benefits
High impact resistance to prevent cracks or deformation
Waterproof and easy to clean
Lighter than traditional materials like plywood or MDF
100% recyclable and environmentally friendly
Polyreflex Recommendation
We recommend 8mm–10mm thick PP Bubble Board with an anti-slip surface for added grip and safety.
2. Door Panel Inserts and Side Covers
Automotive door panels need to be both lightweight and structurally supportive. PP Bubble Board is an excellent core material for door panel inserts, side wall covers, and trim boards.
Why It's Used
Its low density makes it ideal for reducing the overall vehicle weight while still providing a strong base for upholstery and trim layers.
Key Benefits
Lightweight and easy to cut or shape
Good sound insulation properties
Resistant to temperature fluctuations and moisture
Compatible with lamination, printing, and coating processes
Polyreflex Recommendation
Our boards can be CNC-cut and laminated with decorative films, faux leather, or fabric, making them highly customizable for automotive interiors.
3. EV Battery Pack Protection Boards
With the growth of electric vehicles, safety and weight optimization in battery enclosures are critical. PP Bubble Board serves as a non-conductive, lightweight protection layer inside battery pack assemblies.
Why It's Used
It acts as a protective panel that shields delicate battery modules from shock, vibration, and contact with other parts.
Key Benefits
Flame-retardant options available
Non-conductive and corrosion-resistant
Excellent impact absorption
Halogen-free and RoHS-compliant for sustainability
Polyreflex Recommendation
We offer customized flame-retardant PP Bubble Boards that meet UL94 and automotive fire safety standards, tailored for electric and hybrid vehicles.
4. Seat Back Panels and Luggage Partitions
PP Bubble Board is a reliable alternative to heavy materials like plywood or solid plastic in components such as seat back panels, cargo barriers, and luggage compartment dividers.
Why It's Used
Automakers use it to reduce weight while maintaining structure and durability.
Key Benefits
Excellent stiffness-to-weight ratio
Easy to integrate with cushioning and upholstery
No moisture absorption or warping
Sustainable and recyclable
Polyreflex Recommendation
Choose smooth-surface boards for lamination with soft-touch materials or textured boards for direct-use backing components.
5. Protective Packaging for Auto Parts
PP Bubble Board is not only used within the vehicle itself but also in the automotive logistics chain. It's perfect for making custom packaging, dunnage, and dividers for transporting parts like bumpers, headlights, or dashboards.
Why It's Used
Automotive manufacturers and suppliers need reusable packaging that protects components from impact and moisture while lowering logistics costs.
Key Benefits
Shock-absorbing and scratch-resistant
Lightweight to reduce shipping costs
Custom-fit to any part shape
Polyreflex Recommendation
We provide anti-static (ESD) grades for transporting sensitive electronics and components.
From car trunk floors to EV battery protection, PP Bubble Board is reshaping the way automotive components are designed and manufactured. Its lightweight, durable, and recyclable properties make it a superior alternative to traditional materials in both structural and protective applications.
At Polyreflex, we work closely with automotive manufacturers and suppliers to deliver custom PP Bubble Board solutions that meet strict performance, safety, and sustainability standards.
Looking for a lightweight and durable solution for your next automotive project?
Contact Polyreflex today for technical consultation, free samples, and custom orders tailored to your specific needs.
