As car manufacturers look to further reduce their carbon footprint, Autoneum has developed an innovative front trunk solution for battery electric vehicles (BEVs), made entirely from polyester-based textile. The Ultra-Silent Frunk offers significant weight reduction, improved acoustic and thermal insulation, and uses up to 70% recycled material, supporting sustainable and efficient vehicle design. Autoneum, a global technology leader in acoustic and thermal management for vehicles, has already received orders for the new frunk from three major OEMs in Asia and Europe to be built in three BEV models. Series production for two BEVs has been underway in China and Germany since last year.

The global market for BEVs is growing dynamically. With rising demand, the technical development of BEVs is also advancing rapidly. In the front of a BEV, for example, the absence of a combustion engine creates additional storage space under the hood. For this front trunk space, also known as the frunk, Autoneum has developed a fiber-based 100% polyester product. This component is designed for high sustainability and combines lightweight, high mechanical robustness, and excellent acoustic and thermal properties in a functionally integrated design.

“With the innovative frunk made from our environmentally friendly Ultra-Silent polyester textile technology, we are supporting automotive manufacturers in their goal of minimizing the CO₂ footprint of their products by integrating sustainable and lightweight components,” explains Cyro Rovath, global product manager Exterior at Autoneum.

In comparison to conventional frunk systems made of multiple solid plastic parts requiring complex assembly, Autoneum’s Ultra-Silent Frunk is engineered as a single, lightweight, monomaterial component that can be adapted to the technical and aesthetic requirements of automotive manufacturers. The elimination of individual components streamlines both manufacturing and assembly processes while delivering weight reductions exceeding 50% relative to conventional solutions – translating to savings of up to 5 kilograms depending on geometry, number of components and part size.

Moreover, the Ultra-Silent Frunk uses up to 70% recycled material, cutting greenhouse gas emissions by as much as 50% compared to injection molded frunks. Its waste-free production and full recyclability at the end-of-life support the industry’s shift toward a circular economy.

The textile frunk also significantly enhances both acoustic and thermal performance. Its highly sound-absorbing Ultra-Silent material helps reduce noise both inside and outside the vehicle. Additionally, outstanding thermal insulation protects temperature-sensitive items stored in the frunk. Tests conducted under controlled conditions show that ice placed in the Ultra-Silent Frunk stayed frozen for up to 28 hours at an ambient temperature of 30°C, significantly outperforming conventional plastic alternatives. Based on simulations, the Ultra-Silent Frunk offers the potential to improve pedestrian protection and passive safety compared to injection molded plastic solutions due to its higher plasticity.