High-Quality Polycarbonate Solutions for Glazing, Roof, and B-Pillar

For this project, the Exolon Group supplied premium polycarbonate sheet solutions with high optical quality, specifically developed for demanding visual and design applications. The vehicle glazing – including the windshield, rear window, and side windows – is made of transparent solid polycarbonate sheets with a thickness of 5 mm. These ensure clear, distortion-free visibility, high impact resistance, and significantly reduced weight compared to glass.

In the roof area of the e-shuttle, a 6 mm thick polycarbonate sheet in a modern gray tint is used. It is manufactured from a sustainable, plant-based raw material granulate and is ISCC PLUS certified. This clearly demonstrates the project’s commitment to the responsible use of future-oriented materials in tomorrow’s mobility. An IR absorber integrated into the raw material also reduces interior heat build-up under strong sunlight.

Another defining design element is the vehicle’s B-pillar cover, which was extruded from a special polycarbonate compound in a brown-orange shade. The 6 mm thick sheet combines functional stability with a distinctive visual impact.

Excellent Formability and Low Weight as Design and Engineering Advantages

The materials from the Exolon Group used in the fully electric, autonomous e-shuttle approved for road use are characterized by their excellent thermoformability. This allowed the sheet material to be efficiently and precisely adapted to the sleek bus design. In combination with the low weight of the polycarbonate sheets, this opened up additional structural and creative freedom – a decisive advantage for innovative vehicle concepts.

With this project, the Exolon Group impressively demonstrates how modern solid polycarbonate sheet solutions help transform visionary mobility concepts into reality, harmonizing design, engineering, and sustainability.

About UE | STUDIOS
UE | STUDIOS, headquartered in Gaimersheim and Munich, is a globally recognized company for design and engineering services with 7 locations and 21 studios. Since its founding in 1991, the company has established itself as a leading partner for national and international clients. A team of more than 200 employees delivers projects from the initial sketch to fully functional prototypes – ranging from vehicles and aviation to museum installations. With more than 150 show cars produced, UE | STUDIOS is regarded as the world market leader in the production of fully functional vehicle prototypes.

About the SUE project:

SUE (Self-Driving Urban E-Shuttle) is an autonomous, fully electric people mover designed to shape the public transport systems of tomorrow. Developed entirely from the ground up, the vehicle stands as a “Made in Germany” flagship project for technological sovereignty and sustainable mobility. SUE is initiated and led by UE | STUDIOS. As vehicle manufacturer, UE | STUDIOS is responsible for the complete development, design and production of the prototype.

The consortium comprises ten partners: DB Regio, ElringKlinger AG, Faissner Petermeier Fahrzeugtechnik AG, TÜV NORD Mobilität, Fraunhofer EMFT, Technische Hochschule Ingolstadt, Niedersächsisches Forschungszentrum Fahrzeugtechnik, Landkreis Kelheim and IFG Ingolstadt.

The project is funded by the Federal Republic of Germany and the European Union, with the Federal Ministry for Economic Affairs and Energy acting as the funding body based on a resolution of the German Bundestag.