Bcomp flax composites reach series production on Polestar 5

Flax-based composite parts that weigh up to 40% less than the plastics they replace and contain 50% less fossil-based material have entered series production on the Polestar 5, the Swedish brand's four-door electric grand tourer. Swiss supplier Bcomp supplies its ampliTex fabric and powerRibs reinforcement for the front seatbacks and tailgate structure of the vehicle.

The partnership began with the Polestar Precept concept car and has now crossed into large-scale production. The two companies developed a bespoke flax fabric, branded the "Polestar Signature Weave", which serves as both a structural element and a visible design surface. That dual function removes the need for separate decorative layers inside the cabin.

How the materials work

ampliTex is a reinforcement fabric woven from European flax fibres that are processed mechanically rather than chemically. Bcomp says this route cuts the energy and emissions intensity of the material compared with synthetic alternatives such as carbon fibre or glass-reinforced plastics.

powerRibs is a proprietary three-dimensional reinforcement grid made from flax, inspired by the vein structure of leaves. Applied to the rear of a panel, it raises bending stiffness so the part can be made thinner and lighter without losing structural integrity, according to the supplier.

The Polestar 5 seatbacks combine both technologies with natural fibre polypropylene (NFPP), a thermoplastic compound reinforced with plant fibres. Bcomp claims its natural fibre composites can reduce the cradle-to-gate CO₂ footprint of a component by up to 60%, depending on the application.

Validation and end-of-life

All Bcomp components on the vehicle have passed automotive validation covering durability, safety, UV resistance, scratch resistance and long-term ageing. The tailgate structure carries powerRibs, extending natural fibre composites beyond the interior — a comparison worth noting, since carbon fibre parts are typically landfilled or incinerated without energy recovery at end of life.

Bcomp's flax materials offer two disposal routes. Production scraps can be recycled into feedstock for injection moulding, and thermoset flax composites can be incinerated for energy recovery, returning the biogenic carbon stored in the fibre.

What the companies said

Per Martensson, Chief Revenue Officer at Bcomp, said: "Working with Polestar over a number of years has given us the opportunity to show that the path from a material concept to a series-production component can be long and rigorous but is ultimately worth it. The Polestar 5 seatbacks have a combination of lightweighting performance, reduced carbon footprint, and design for end-of-life that conventional composites cannot offer."

Maria Uggla, Head of CMF design at Polestar, said: "With the Polestar 5, we aim for a performance-focused Grand Tourer, without compromising on our sustainability targets. Bcomp's materials have allowed us to build a performance-focused seatback as well as not compromise our sustainability requirements."

What to watch next

The claims rest on supplier figures, so the marker to track is volume: whether the Signature Weave and powerRibs parts hold up across thousands of vehicles in global markets, and whether other OEMs follow Polestar from concept-stage natural fibre parts into validated series production.