When you hear the term “plastic car” today, you might picture something cheap, flimsy, or disposable. But in the resource-scarce landscape of post-war East Germany, “plastic” wasn’t a pejorative—it was the future. Engineers were pioneering a revolutionary material that was not only tough and lightweight but was also derived from some of the most unassuming industrial and agricultural byproducts.
The car was the AWZ P70, and its body was crafted from a remarkable composite called Duroplast. This wasn’t the flimsy plastic of modern stereotypes; it was a testament to ingenuity in an era of scarcity. Here are five surprising truths about this forgotten wonder material that challenge everything we think we know about “plastic” cars.
Its Core Ingredients Were Coal Tar and Cotton
The manufacturing process for the P70’s body panels began not in a high-tech lab, but with the byproducts of heavy industry. The process began with phenol—a substance derived from the distillation of brown coal tar—which was mixed with other chemicals to create a synthetic resin. This material was then cooled, shattered, and milled into a fine powder known as “plastar resin.”
This powdered resin served as a binding agent. It was mixed with a filler material—waste cotton fibers from the region’s textile industry—and the resulting mixture was poured into molds. Under immense heat and pressure, these simple ingredients fused together to form strong, durable, and lightweight car body parts. This was a masterful example of early composite science, creating a thermosetting plastic from the most basic industrial feedstocks available.
You Could Repair Body Damage With a “Miracle Paste”
Unlike a conventional car from that era, which would require a mechanic with a hammer and tongs to beat out a dent, the P70 offered a much simpler solution. A surviving promotional film from the era paints a compelling picture: a mechanic, armed not with metalworking tools but with a simple tin of “wunderpaste” (miracle paste), seamlessly repairs a gaping hole in a body panel.
For the average car owner, this simplified repair process was a significant advantage. The ability to quickly and easily mend damage without the need for complex and expensive bodywork was a revolutionary feature, saving both time and money.
It Was Exceptionally Durable
Despite its humble origins, Duroplast was a remarkably resilient material. To prove its strength, durability tests subjected the material to extreme and continuous stress. In one dramatic demonstration, a model was run continuously for months while being struck by a 50 kg hammer and rolled over by a 100 kg roller. Even after this punishing, prolonged trial, the material retained its elasticity and did not shatter.
This toughness translated into several key benefits for car owners:
- Elasticity: It could absorb impacts that would permanently dent sheet metal.
- Low Weight: Using Duroplast saved 10 kg of steel per vehicle, a significant saving at the time.
- Good Insulation: The material provided better thermal and acoustic insulation than a standard metal body.
This impressive durability stands in stark contrast to the modern perception of plastic as a weak or brittle material.
The Same Base Material Was Used in Locomotives
The synthetic resin at the heart of Duroplast was astonishingly versatile, used to create everything from simple pipes, handwheels, and sealing caps to heavy-duty industrial components. The technology wasn’t just for making car bodies; it was a robust solution for engineering challenges where strength and durability were paramount.
When the same base resin was used to impregnate layers of canvas, which were then pressed together, it created an extremely tough composite. This material was strong enough to be manufactured into parts like axle bearing slide plates and gears for locomotives. The same basic chemistry that formed the skin of a passenger car was also used to create critical components for a freight train.
The Makers Still Gave a Charming Word of Warning
After showcasing the P70’s futuristic material, impressive toughness, and innovative features, the narrator of the original film ends with a refreshingly pragmatic piece of advice for the proud new owners. Despite all the proof of the car’s resilience, they offered a charming and very human dose of reality.
In spite of everything, it’s better not to get into an accident. Things can still go wrong, and that would be a shame, not just for the beautiful car.
This honest warning acknowledges that even the most innovative technology is subject to the unpredictable realities of the road, reminding drivers that caution is always the best policy and adding a wonderful touch to the presentation.
Conclusion: A Lesson in Resourcefulness
The AWZ P70 and its Duroplast body are more than just historical curiosities; they represent a powerful lesson in resourcefulness. By transforming humble materials like coal tar and waste cotton into a durable and practical automotive material, its creators demonstrated what is possible when ingenuity is applied to the challenge of scarcity. The story of Duroplast serves as a powerful reminder that the definition of “waste” is merely a failure of imagination.
This remarkable material was also used in East Germany’s iconic Trabant car. Discover its story in Built to Last: The Contradictory Genius of the Trabant.
What can modern manufacturing learn from this era of turning humble materials into durable, innovative products?