Autoneum is a key supplier of interior and exterior components in the new Polestar 5 launched at IAA Mobility 2025 in Munich in September and now available in 24 markets.

The electric grand tourer sports car features several innovations in lightweight, fully recyclable polyester-based components that ensure a superior driving experience.

Over the past five years, Autoneum experts in sales, research and technology, development centres and programme management have worked closely with Polestar R&D teams to develop a suite of 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 recycled polyester content and the latex-free, low-waste manufacturing process developed for them significantly reduces CO2 emissions across their lifecycles. In electric vehicles, these components also enable easier end-of-life recycling and battery access.

The partnership has paved the way for several new Autoneum innovations specifically tailored for the Polestar 5. The Ultra-Silent frunk and frunk tray with knitted PET 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 superior acoustic performance. The Ultra-Silent hush panels, mounted under the interior cockpit, deliver both noise reduction and design flexibility. 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,” says Kevin Van Gorp, technical expert at Autoneum. “We were able to provide the customer with expertise from across Autoneum’s global footprint, from our early work at the Polestar engineering centre 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.”

“Our vehicles are the result of Scandinavian innovation and our design philosophy is rooted in pure minimalism,” adds Marria Uggla, head of colour, material and finish design at Polestar. “As a modern premium EV brand, our goal is to redefine luxury by designing sustainable, minimalist materials with innovative aesthetics. We believe in the power of design to encourage consumers to make more sustainable choices.”

www.autoneum.com