{"id":53449,"date":"2026-04-20T09:34:17","date_gmt":"2026-04-20T07:34:17","guid":{"rendered":"https:\/\/composites-united.com\/?p=53449"},"modified":"2026-04-20T10:00:56","modified_gmt":"2026-04-20T08:00:56","slug":"hybrid-lightweight-sustainable-and-exceptionally-safe-headrest-for-car-child-seat","status":"publish","type":"post","link":"https:\/\/www.composites-united.com\/en\/hybrid-lightweight-sustainable-and-exceptionally-safe-headrest-for-car-child-seat\/","title":{"rendered":"Hybrid, lightweight, sustainable, and exceptionally safe headrest for car child seat"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"53449\" class=\"elementor elementor-53449 elementor-53437\" data-elementor-post-type=\"post\">\n\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-6ea2203 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"6ea2203\" data-element_type=\"section\" data-e-type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-5f77c6a\" data-id=\"5f77c6a\" data-element_type=\"column\" data-e-type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-b391282 elementor-widget elementor-widget-text-editor\" data-id=\"b391282\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><strong>If all child seat headrests were produced using lightweight technologies, a substantial reduction in carbon emissions could be achieved across the automotive and transport sectors. By replacing virgin PA6 with 100 % recycled feedstock reinforced with unidirectional tapes, manufacturers can significantly reduce CO\u2082 emissions while maintaining or even improving mechanical performance.\u00a0<\/strong><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-0725c5b elementor-widget elementor-widget-text-editor\" data-id=\"0725c5b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>This manufacturing approach delivers a key benefit of up to a 34 % reduction in CO\u2082 footprint compared to a headrest made from virgin PA6, together with a 20 % weight reduction versus conventional injection-molded parts. Importantly, the lightweight solution maintains the same level of impact energy absorption as the virgin material, ensuring uncompromised safety.<\/p><p>Additional advantages include the use of recycled marine waste and the implementation of circular design principles for safety-critical components, strengthening both environmental responsibility and longterm sustainability.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<section class=\"elementor-section elementor-inner-section elementor-element elementor-element-0490dfe elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"0490dfe\" data-element_type=\"section\" data-e-type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-50 elementor-inner-column elementor-element elementor-element-67030b7\" data-id=\"67030b7\" data-element_type=\"column\" data-e-type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-0fefe77 elementor-widget elementor-widget-image\" data-id=\"0fefe77\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"1200\" height=\"1245\" src=\"https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz.jpg\" class=\"attachment-1536x1536 size-1536x1536 wp-image-53440\" alt=\"\" srcset=\"https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz.jpg 1200w, https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz-289x300.jpg 289w, https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz-987x1024.jpg 987w, https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz-768x797.jpg 768w\" sizes=\"(max-width: 1200px) 100vw, 1200px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-df2cc64 elementor-widget elementor-widget-text-editor\" data-id=\"df2cc64\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: center;\">Headrest (\u00a9 LSE)<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t<div class=\"elementor-column elementor-col-50 elementor-inner-column elementor-element elementor-element-3d65f86\" data-id=\"3d65f86\" data-element_type=\"column\" data-e-type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-5c842f5 elementor-widget elementor-widget-image\" data-id=\"5c842f5\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"1200\" height=\"1095\" src=\"https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz-1.jpg\" class=\"attachment-1536x1536 size-1536x1536 wp-image-53444\" alt=\"\" srcset=\"https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz-1.jpg 1200w, https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz-1-300x274.jpg 300w, https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz-1-1024x934.jpg 1024w, https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze_Kindersitz-1-768x701.jpg 768w\" sizes=\"(max-width: 1200px) 100vw, 1200px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-c096af9 elementor-widget elementor-widget-text-editor\" data-id=\"c096af9\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: center;\">Child seat with headrest (\u00a9 LSE)<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<div class=\"elementor-element elementor-element-15ec79b elementor-widget__width-initial elementor-widget elementor-widget-text-editor\" data-id=\"15ec79b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><strong>Project content <\/strong><\/p><p>The hybrid composite child seat headrest represents a breakthrough in sustainable lightweight design. It combines mechanically recycled polyamide 6 (PA6) with advanced unidirectional (UD) tape laminates to achieve outstanding impact performance in a safety-critical application. This innovation demonstrates that high-performance safety components can successfully integrate mechanically recycled materials without compromising safety.\u00a0<\/p><p>Manufactured using an efficient single-step hybrid molding process, the UD tape insert is thermoformed and directly back-injected with post-consumer recycled PA6, integrating the support structure for both headrest and backrest. This enables a lean, cost-effective, and scalable production route for sustainable safety components.<\/p><p>Discarded fishing nets collected in Africa (by the Sea2see Foundation) are used, reducing ocean waste and its negative impact on marine life. Plus, it will add more value creation.\u00a0<\/p><p><strong>Evaluation<\/strong><\/p><p>The project also demonstrates how interdisciplinary collaboration along the entire value chain can lead to innovative, sustainable solutions for safety-critical applications. Material development process integration, component design, and environmental impact assessment were considered holistically and successfully implemented in a functional demonstrator.<\/p><p>By combining recycled polymers with composite technology, new application fields for post-consumer recycled plastics are unlocked. The main value lies in achieving a 34 % CO\u2082 reduction and 20 % mass reduction compared to a conventional virgin PA6 headrest, without any loss in impact energy absorption.<\/p><p>So the project demonstrates that sustainability, safety, and lightweight construction are compatible with one another. The result is a scalable pathway toward circular, lightweight, and sustainable design across industries.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-881de9f elementor-widget elementor-widget-spacer\" data-id=\"881de9f\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"spacer.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-spacer\">\n\t\t\t<div class=\"elementor-spacer-inner\"><\/div>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-40564b2 elementor-widget elementor-widget-image\" data-id=\"40564b2\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"631\" height=\"546\" src=\"https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze-child_seat.png\" class=\"attachment-large size-large wp-image-53442\" alt=\"\" srcset=\"https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze-child_seat.png 631w, https:\/\/www.composites-united.com\/wp-content\/uploads\/2026\/04\/ThermoPre_Kopfstuetze-child_seat-300x260.png 300w\" sizes=\"(max-width: 631px) 100vw, 631px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-3749e4c elementor-widget elementor-widget-text-editor\" data-id=\"3749e4c\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: center;\">Child seat with headrest (\u00a9 LSE)<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-ae3062f elementor-widget-divider--view-line elementor-widget elementor-widget-divider\" data-id=\"ae3062f\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"divider.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-divider\">\n\t\t\t<span class=\"elementor-divider-separator\">\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2968f8b elementor-widget elementor-widget-text-editor\" data-id=\"2968f8b\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p>Developed within the EU-funded RaRe\u00b2 project (www.raresquare.eu). Extensive crash testing confirmed equal energy absorption compared to virgin material.<\/p><p><strong>Project partners:<\/strong> thermoPre Engineering GmbH; LSE GmbH; Avionaut \u2013 L. Karwala sp. k.; Chemnitz University of Technology \u2013 Institute of Lightweight Structures; DOMO Engineering Plastics Europe S.p.A. Germany; Innovation Cluster Circular Saxony \u2013 represented by Circular MTC e.V.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-b2642c4 elementor-widget-divider--view-line elementor-widget elementor-widget-divider\" data-id=\"b2642c4\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"divider.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"elementor-divider\">\n\t\t\t<span class=\"elementor-divider-separator\">\n\t\t\t\t\t\t<\/span>\n\t\t<\/div>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-64908c7 elementor-widget elementor-widget-text-editor\" data-id=\"64908c7\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><strong>Contact:<\/strong><\/p><p>thermoPre ENGINEERING GmbH, <br \/>Sebastian Iwan, CEO<br \/>+49 176 20 74 23 28<br \/><a href=\"mailto:sebastian.iwan@thermopre-gmbh.de\" target=\"_blank\" rel=\"noopener\">sebastian.iwan@thermopre-gmbh.de<\/a><br \/><a href=\"http:\/\/thermopre-engineering.de\" target=\"_blank\" rel=\"noopener\">thermopre-engineering.de<\/a><\/p><p>\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>If all child seat headrests were produced using lightweight technologies, a substantial reduction in carbon emissions could be achieved across the automotive and transport sectors. By replacing virgin PA6 with 100 % recycled feedstock reinforced with unidirectional tapes, manufacturers can significantly reduce CO\u2082 emissions while maintaining or even improving mechanical performance.\u00a0 This manufacturing approach delivers [&hellip;]<\/p>\n","protected":false},"author":5,"featured_media":53442,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[30,171],"tags":[],"main-cat":[144,34],"bildung":[],"forschungs-cat":[],"class_list":["post-53449","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-info","category-top-news","maincategory-cu","maincategory-cu-ost"],"acf":[],"aioseo_notices":[],"aioseo_head":"\n\t\t<!-- All in One SEO 4.9.10 - aioseo.com -->\n\t<meta name=\"robots\" content=\"max-image-preview:large\" \/>\n\t<meta name=\"author\" content=\"Julia Konrad\"\/>\n\t<link rel=\"canonical\" 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