Wir zerlegen ein Modellauto in seine Komponenten – besucht uns im Aachener C.A.R.L.
At the Science Night at C.A.R.L. Aachen on November 14, 2025, we will show you how exciting products are made from plastic – and in a very practical way using a model car.
Each part of our model car represents a different manufacturing process and material. Here you can find out how the individual components are manufactured – from the body to the tires. Take a look at which component is manufactured in which process.
© IKV
Car body – Thermoforming
The body you may be holding in your hands right now is produced using the thermoforming process. A polystyrene film (0.8 mm thick) is heated under a ceramic radiator until it is soft enough to be placed around a mold using a vacuum. After cooling, the shape is permanently retained – and the body is finished! The windows of the car are also manufactured in this way. The film itself is produced in the flat film extrusion process – from the raw granulate to the glossy plastic web.
👉 You can thermoform your own car body at the Science Night!
Steering components – Injection molding
The steering parts are manufactured using the injection molding process – one of the most important processes in plastics technology. In this process, molten plastic is injected under high pressure into a mold, where it cools and takes on its final shape. The result: precise, stable and ready-to-use components that are ejected automatically.
💡 The same process is also used for the housings of electrical appliances, connectors or toy figures.
Frame – additive manufacturing (3D printing)
When it comes to complexity or small quantities, additive manufacturing – better known as 3D printing – is the way to go. A plastic filament is heated, liquefied and built up layer by layer according to a digital model. This means that even complicated shapes can be produced without the need for molds.
💡 In the IKV workshop “3D printer driving license”, our students learn what to look out for when designing in order to print stable and functional components.
Base plate – vacuum infusion with carbon fibers
If a component needs to be particularly light and very rigid at the same time, carbon fiber reinforced plastic (CFRP) is the right choice. For this purpose, carbon fabrics are stacked in specific layers, impregnated with synthetic resin under vacuum and then cured. The result is a high-performance component – lightweight, robust and ideal for your model car.
💡 This process is also used in aircraft and racing car construction.
Impact elements (bumpers) – Polyurethane processing
The bumpers of your model car are made of polyurethane (PUR) – a material that can be used as foam, elastomer or hard plastic. A two-component PUR system is mixed for the impact elements. A chemical reaction produces CO₂, which inflates the foam. The result: elastic, shock-absorbing components, just like those used in real cars.
💡 The foam can be made softer or firmer with the right combination of components.
Tires – Rubber production
To get the model car rolling, it naturally needs tires. They are made of rubber, which is first mixed with rubber and other ingredients. The material is then extruded, shaped and vulcanized in a mould under pressure and heat, turning the soft rubber into elastic rubber.
💡 In the IKV lecture “Rubber Technology”, students can even produce and test their own tire compound.
Does that sound exciting to you? Then visit us at the Science Night on 14.11.2025 at our stand in the C.A.R.L. We look forward to hearing from you and answering your questions!