What kind of plastic is used for car bumpers?
The outer bumper cover is predominantly polypropylene-based, typically in thermoplastic olefin (TPO) blends. Some models use ABS or PC-ABS blends, but PP-TPO remains the standard for mass-market bumpers due to cost, weight, and recyclability. Behind the cover, energy-absorbing foam and a structural bumper beam complete the system.
This article explains the materials behind modern bumper design, the reasons these plastics are chosen, and how variations appear across different vehicles and regions.
Common bumper-cover materials
The visible part of a bumper — the cover — is most often made from polypropylene-based plastics. Engineers blend PP with elastomer modifiers to create a thermoplastic olefin (TPO) that balances stiffness, impact resistance, and paint adhesion. Some higher-end or specialty models use other plastics for performance or aesthetic reasons.
- Thermoplastic olefin (TPO) blends based on polypropylene (PP) with elastomeric impact modifiers (such as EPDM or other polyolefin elastomers) to provide impact resistance and flexibility.
- ABS or PC-ABS blends, used on certain models or trims to achieve a shinier finish or greater heat resistance, at higher cost.
- Less commonly, polycarbonate (PC) or PC-ABS blends in niche designs where higher rigidity or clarity is desired in integrated lighting areas, though not typical for standard bumpers.
Across the industry, PP-TPO remains the default choice for the outer bumper cover because it delivers a favorable balance of cost, weight, paintability, and recyclability.
Other components of the bumper system
Beyond the outer cover, the bumper assembly includes energy-absorbing material and a structural beam. The energy absorber sits behind the cover and is designed to deform on impact, protecting the vehicle and occupants.
- Energy-absorbing foam: commonly polyurethane (PU) foam or expanded polypropylene (EPP) foam to cushion impact and control intrusion.
- Bumper beam: typically steel or aluminum in most cars, with some models using composite materials for weight reduction and improved energy management.
- Surface finishes and coatings: bumper covers are painted or coated to match the vehicle color and may include protective films or textures for durability.
In practice, automakers tailor the material mix to balance safety, cost, weight, and repairability, with PP-based bumper covers remaining the standard for mass-market vehicles.
Summary
Today's car bumpers rely mainly on polypropylene-based plastics (TPO) for the outer cover, with ABS/PC-ABS as alternatives in some models. Behind the cover, energy-absorbing foams and a reinforcing bumper beam form the rest of the system, all designed to manage crash energy, keep weight down, and maintain color and finish across a wide range of vehicles.
What is the difference between ABS plastic and polypropylene?
ABS is a stronger, more impact-resistant plastic with a better surface finish, while polypropylene (PP) is more flexible, has better chemical resistance, and higher heat resistance. Choose ABS for durability and aesthetics, and PP for applications needing flexibility, chemical resistance, or a higher melting point.
ABS (Acrylonitrile Butadiene Styrene)
- Strengths: Higher impact resistance, good toughness, and better stiffness. It has a glossy surface that is easy to paint, making it ideal for visible parts.
- Weaknesses: Lower heat resistance than PP and prone to scratching.
- Best for: Applications requiring high durability and a good finish, such as LEGO bricks, electronics housings, and automotive interior parts.
Polypropylene (PP)
- Strengths: Higher heat resistance, excellent chemical resistance, and greater flexibility. It is also lighter and generally less expensive.
- Weaknesses: Less impact-resistant than ABS and has a duller surface that is harder to paint or coat.
- Best for: Applications needing chemical resistance and flexibility, like food containers, storage bins, and automotive under-hood components.
What type of plastic is used on car exterior?
Polypropylene. Polypropylene is used the most frequently of any plastic in automotive manufacturing. Being a thermoplastic polymer, it can easily be formed into almost any shape. It has excellent chemical and heat resistance and is generally resistant to impact.
How to identify automotive plastics?
Today, we can identify the plastic parts of a vehicle through a kind of number plate or identification code located inside, which specifies the exact composition of the part (type of material and reinforcement load if any). This information is delimited by the symbols “>” and “<“.
What plastic is used for car bumpers?
Polycarbonate
Polycarbonate. Like polypropylene, polycarbonate is so resistant to impact that it is often used for car bumpers and headlight lenses. This kind of car plastic is highly resistant to weathering, able to handle conditions from rain and snow to heat and cold.
