EPP Automotive Solutions That Balance Weight, Safety and Production-Readiness

Custom Expanded Polypropylene components for impact protection, thermal control and interior comfort across ICE and EV platforms

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EPP Pioneers since 1990

K. K. Nag introduced EPP moulding technology to the Indian automotive sector in 1990. The first production part followed in 1992 when sun visor cores were supplied for a Spanish programme to a car interior manufacturer and supplier.

What Sets Our Automotive Expertise Apart

Three decades of applied EPP in automotive
In-house tool design and manufacturing for faster developments
Multi-cavity moulds and stable series production
APQP, FMEA, PPAP and end-of-line checks that comply with OEM practices
K. K. Nag Operational Excellence (KOpEx) or Lean and Green Manufacturing

years of EPP experience

customers across multiple sectors

Our Accreditations

What EPP Delivers for Modern Vehicles

Lightweight

Reduces mass, which supports fuel economy and EV range targets

Shock absorbent

High energy absorption for crash and head-impact protection

Thermally and chemically resistant

Stable through service temperatures; resistant to oils and coolants

Reusable and recyclable

Supports circular goals for recyclable automotive materials

Damp Resistant

Closed-cell structure resists moisture ingress for long service life

Why Customise EPP Solutions with K. K. Nag?

We align part performance with programme targets through controlled density selection, mould design and validation.

Build to Print

Starting from customer drawings, we conduct DFM reviews, tool design, validation and series production.

Material Density

Tuned bead density to achieve target stiffness, impact response and NVH.

Shape and Size

Moulded in varied shapes and sizes — from compact inserts to large modules — with precision and consistent quality.

Prototyping and Testing

Prototype quickly with hand-cut or CNC samples, using soft tooling for field trials and validation.

Performance Specifications

Defined with the customer and validated to relevant standards and test methods at DV, PV and PPAP.

Range of Automotive Applications

Battery Cover (EV/Hybrid)

Lightweight EPP battery covers that absorb impact, support thermal insulation and protect battery modules with stable, durable performance.

Bumpers and Energy Absorbers

EPP bumper cores and crash zone blocks that offer protection and higher safety ratings for front and rear modules.

Door Panel Inner Filler

EPP door panel components that provide energy absorption, structural support and accurate integration for interior trims and hardware.

Floor Spacer

Structural EPP spacers that maintain floor height accuracy while contributing to weight reduction and vibration isolation.

Headliner

EPP headliners support noise and vibration reduction and offer structural reinforcement with minimal weight increase compared to conventional materials.

Headrest Core

Precision-moulded EPP headrest cores providing lightweight strength, comfort, support and controlled energy absorption.

Parcel Shelf Corer

Dimensionally-stable EPP parcel shelf covers offering lightweight support, acoustic insulation and consistent cabin fit.

Seat Core

EPP seat cores engineered to deliver lightweight structural support, long-term durability and controlled comfort performance.

Spare Wheel Organiser

Lightweight EPP organisers designed to securely hold spare wheels, tools and accessories while reducing noise and vibration.

Steering Column Pad

Energy-absorbing EPP pads engineered to meet occupant impact protection requirements around the steering column.

Sun Visor Core

Proven first application in India; lightweight cores with stable form and surface bonding.

Tool Kit/Tool Caddy Tray

Moulded EPP trays that organise vehicle tools efficiently while minimising rattling and ensuring durability.

Trunk Floor Support

Load-bearing EPP supports designed to reinforce trunk floors while enabling lightweight construction and modular assembly.

Wheel-House Liner Insert

EPP liner inserts that reduce noise, resist moisture and debris and maintain strength under road impact and vibration.

Case Studies and Success Stories

Team VIT – Veloce Racing India

K. K. Nag is partnered with Team VIT – Veloce Racing India to supply lightweight EPS prototypes and EPP components that improve stiffness-to-weight ratio and impact behaviour, contributing to their back-to-back win in the EV category at the F1-graded Buddh International Circuit.

Download the full case study

Mahindra XUV700

For a critical interior component, K. K. Nag engineered an EPP replacement that reduced mass from 1.4 kg to 380 g. The solution passed extended fitment trials and 2,000-cycle durability tests, supporting higher efficiency and safety performance targets.

Download the full case study

Force Motors

Force Motors required a quiet and secure tool stowage system. K. K. Nag developed a custom EPP kit with precise cavities that prevent movement and abrasion. The design was then standardised to serve Gurkha, Trax and Urbania assemblies with a single kit.

Download the full case study

Ready to Align Weight, Safety and Timelines?

Frequently Asked Questions

We follow and often do better than the tolerance standards developed by raw-material manufacturers for foamed parts. Tolerance bands are reviewed at DFM and correlated to fixtures during PPAP.

Yes. Designs can include clip features, local inserts or over skins. Adhesive and film bonding routes are qualified during development.

We align to customer test methods for energy absorption, compression set, thermal insulation and fire or fogging where required. Correlation is established during prototypes and PPAP.

Yes. We design EPP dunnage for multiple products such as battery packs, sun roofs, stators and rotors, with cleaning and reuse in mind.