Lehvoss Smart Resourcing: Lightweight Compounds at Fakuma

Plastics and cost efficiency Levoss presents four application examples for Smart Resourcing at Fakuma

2026-09-21 Source: Lehvoss 2 min Reading Time

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From agricultural drones to wearable exoskeletons, material choices influence weight, energy consumption and manufacturing costs. At Fakuma, Lehvoss will present four applications showing how specialised compounds can replace metals, simplify production and reduce material use.

Headlight housing. Reduced weight and higher productivity thanks to Luvobatch — blowing agent masterbatches.(Source: Lehvoss) — Headlight housing. Reduced weight and higher productivity thanks to Luvobatch — blowing agent masterbatches.
(Source: Lehvoss)

The Lehvoss Group has introduced Smart Resourcing, a portfolio of selected compounds aimed at plastics processors facing price pressure, volatile raw material costs and supply chain uncertainty. According to the company, the offering can reduce material costs by 10 to 20 per cent while maintaining its existing quality standards.

At Fakuma, from October 12 to 16, the offering becomes tangible. Four exhibits at booth B1-1109 show how cost savings and performance gains come together. „Our customers are under cost pressure, not in need of explanations. That is why at Fakuma we are showing components made from materials that add up“, says Dr. Harald Hunke, Commercial Director Europe at Lehvoss Compounds.

Agricultural drone

Propeller blades have to be stiff. Every bit of flex under load costs energy that should go into thrust. The blades of this autonomous agricultural drone are made of carbon-fiber-reinforced compounds based on Lehvoss XCF technology — stiffer and stronger than standard CF-reinforced thermoplastics and composites. Less energy per revolution means more flight time, more range, less noise.

Headlight housing

Blowing agent masterbatches foam the part inside the mould — improving dimensional stability at the same time. Volume is created on the inside, where no load is applied, with unchanged impact strength and stability. On large injection-molded parts such as door panels or light housings, part weight drops by up to 25 percent. Including the headlight housing shown here. The second effect isn’t in the part. It is found in the costing: cycle time falls and the processing temperature can be lowered. Same machine, more parts per shift, less energy.

Work light

The housing of a work light used to be an aluminium die casting. It had to be deburred and painted, and it was sourced from Asia. Today it’s an injection-moulded part made of thermally conductive plastic, produced in-house. Deburring and painting are gone; the colour is in the material. Heat still dissipates, thanks to a thermally conductive compound.

Exoskeleton

An exoskeleton takes the load off the worker — and must not become one itself. In metal, that is hard to achieve. In plastic, it is straightforward: three metal components have been replaced. Struts and a gear housing made of metal-replacement compounds, and a drive gear wheel made of tribologically modified material.

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