Why PP Bubble Board Is the Ideal Material for Car Trunk Liners and Floor Panels

In today's automotive industry, the demand for lightweight, durable, and eco-friendly materials is rapidly growing. As manufacturers strive to reduce vehicle weight and improve energy efficiency, they are also looking for sustainable alternatives to traditional materials. Among these alternatives, PP Bubble Board is emerging as a smart solution — especially for applications such as car trunk liners and floor panels.

In this article, we'll explain why PP Bubble Board is the ideal material for these parts and how it compares to conventional options like MDF, plywood, and PVC foam.

What Is PP Bubble Board?

PP Bubble Board is a type of polypropylene sandwich panel featuring a three-layer structure: solid outer skins and a unique bubble-shaped core in the middle. This design provides excellent strength-to-weight ratio, making it a preferred material for industries such as automotive, logistics, packaging, and more.

Unlike traditional solid or corrugated plastic sheets, PP Bubble Board combines rigidity, impact resistance, and light weight, all while being 100% recyclable. At Polyreflex, we've been manufacturing high-quality PP Bubble Boards for over 18 years, offering various customization options to meet automotive industry standards.

If you're new to this material, check out our introductory article: What Is PP Bubble Board and What Are Its Advantages?.

Why Use PP Bubble Board for Trunk Liners and Floor Panels?

1. Lightweight for Better Fuel Efficiency

PP Bubble Board is significantly lighter than MDF, plywood, and PVC foam. Reducing component weight in vehicles directly translates to improved fuel economy and electric vehicle range, which is critical in the era of sustainable mobility.

2. High Impact Resistance

Car trunk liners and floor panels need to withstand heavy luggage, tools, and daily wear. PP Bubble Board offers excellent impact resistance and does not deform easily, ensuring long-lasting performance even under rough conditions.

3. Waterproof and Chemical Resistant

One of the key challenges in automotive interiors is exposure to moisture, oil, and chemicals. PP Bubble Board is naturally waterproof, doesn't absorb moisture, and resists chemical corrosion — making it ideal for trunk floors that may encounter spills or dirt.

High Strength PP Bubble Boards

Easy to Process PP Bubble Boards

4. Excellent Thermoformability

This material can be heat-formed, cut, drilled, or laminated into complex shapes, which allows it to precisely fit the curves and edges of modern car trunk designs. Polyreflex also provides CNC cutting and molding services for accurate part customization.

5. Cost-Effective and Recyclable

Compared to aluminum composite panels or engineering-grade plastics, PP Bubble Board is more economical while still delivering impressive performance. It is also fully recyclable, contributing to your brand’s sustainability goals.

Comparison: PP Bubble Board vs Traditional Materials

Feature	PP Bubble Board	MDF / Plywood	PVC Foam Board	Corrugated Plastic
Weight	★★★★☆	★★☆☆☆	★★★☆☆	★★★☆☆
Impact Resistance	★★★★☆	★★★☆☆	★★★☆☆	★★☆☆☆
Water & Chemical Resistance	★★★★★	☆☆☆☆☆	★★★★☆	★★★☆☆
Recyclability	★★★★★	☆☆☆☆☆	★★★☆☆	★★★☆☆
Thermoformability	★★★★☆	☆☆☆☆☆	★★★★☆	★☆☆☆☆
Cost-Effectiveness	★★★★☆	★★☆☆☆	★★★☆☆	★★★☆☆

Real-World Applications and Case Study

At Polyreflex, our PP Bubble Board has been widely used in:

Trunk floor panels for passenger cars and commercial vehicles

Cargo liners that offer a flat, strong surface for storage

Under-floor compartments for spare tire storage or hidden storage trays

Seat back panels that require high rigidity, lightweight structure, and aesthetic surface finish

PP Bubble Board Trunk Floors

For one of our European automotive clients, we supplied 10mm PP Bubble Boards with anti-slip surface textures, CNC-cut to exact shapes. These panels were lightweight yet rigid enough to carry up to 80kg loads in daily use, with no signs of fatigue or wear after long-term testing.

In another project, we provided customized PP Bubble Boards for automotive seat back panels, meeting the customer's strict requirements on dimensional precision and appearance. The boards were laminated with a leather foam to match the interior design, offering both mechanical strength and a clean, high-end finish.

Customization Options from Polyreflex

To suit different automotive applications, Polyreflex offers full customization:

Thickness: From 2mm to 15mm

Weight: 1200gsm to 4000gsm

Colors: Black, grey, white, and custom colors

Surface: Matte, anti-slip, or textured finish

Processing: CNC cutting, drilling, lamination, and thermoforming

Add-ons: Flame retardant, UV-resistant, or anti-static options available

Custom PP Bubble Board

Customized Thickness PP Bubble Board

What Traditional Materials Can PP Bubble Board Replace?

PP Bubble Board is a strong alternative to:

Plywood / MDF: Avoids moisture absorption and heavy weight

PVC Foam Board: Offers better recyclability and lighter structure

Corrugated Paperboard: Withstands more load and moisture

Solid PP or PE Sheets: Achieves same stiffness with lower material cost

PVC Foam Board

Corrugated Paperboard

This makes it an ideal upgrade in terms of both performance and sustainability.

If you're looking for a lightweight, durable, cost-effective, and environmentally friendly solution for automotive trunk liners and floor panels, PP Bubble Board is the answer. Its high strength, easy processability, and full recyclability make it a future-ready material for today's and tomorrow's automotive innovations.

Contact Polyreflex Today

Want to learn more or request a free sample?

Reach out to our team and discover how PP Bubble Board can elevate your automotive solutions.