Sonnenwagen and Covestro: Shaping the mobility of the future together
The company has also been the main sponsor since 2018 and the success speaks for itself: At the European Championship, the iLumen European Solar Challenge 2024 in Zolder, Belgium, the team narrowly missed victory and finished second and third with their two cars Photon and Adelie. The experiences from back then have been incorporated into the current generation of the race car: The "Æthon". With Æthon, the team secured an impressive fourth place at the 2025 World Solar Challenge in Australia.
The Cockpit Canopy
The transparent cockpit canopy is made of impact-resistant polycarbonate. It is lightweight, dimensionally stable, UV-resistant and protects drivers - with full visibility and minimal weight.
The Steering Wheel
A polyurethane-based steering wheel cover ensures a precise grip. The more sustainable coated textile is water-based and contains partially bio-based components.
The Coating
The Sonnenwagen is coated with a high-solids coating that hardens efficiently at room temperature - it saves energy and time, reduces emissions and is based on more sustainable raw materials.
The Battery
Battery Cell Holder
A thermally conductive polycarbonate protects the battery from overheating - it dissipates heat, insulates against electricity and extends the battery's life.
Battery Damping
Elastomers made from mass-balanced recycled material surround the battery like a protective cushion - for full function even under maximum load.
The Headlamp Cover
Severe weather and stone chips are part of the route in the Australian outback. The headlamps have to withstand this - which is why they are protected by covers made of highly impact-resistant polycarbonate.
The Crash Absorber
The front section of the Sonnenwagen contains a polyurethane foam that specifically absorbs energy in the event of an emergency. It deforms under pressure - and thus protects the interior of the vehicle.
The LED Heat Sink
Where metal would be too heavy, a polycarbonate with high thermal conductivity is used. It cools the LED lighting technology in the Sonnenwagen reliably and without conducting electricity.
One-Year Construction Phase
For one year, Team Sonnenwagen worked intensively on the construction of the "Æthon". The goal: successful participation in the Bridgestone World Solar Challenge 2025 in Australia – a goal that the team has secured with a top placement. The solar car race is probably the toughest competition of its kind worldwide and leads over a distance of more than 3,000 kilometers through the Australian Outback from Darwin to Adelaide – without any fuel or charging station.
More than 50 teams from internationally renowned universities from 24 countries compete against each other with their solar cars in the race. Victory is determined not only by speed – Team Sonnenwagen's vehicles can reach speeds of up to 120 kilometers per hour – but also by the optimal use of available solar energy. In any case, the project is a valuable experience for the Aachen team and impressively demonstrates their commitment to developing future mobility concepts.
We are incredibly proud of what we have achieved. Just finishing this race is an enormous achievement – and with Æthon, we made it into the ranks of the world’s best teams. Our vehicle proved itself under extreme conditions, and we are taking away many important insights.
Multidisciplinary Team
Even during Æthon's one-year development period, teamwork led to success. Aerodynamics, electrical engineering, driving strategy, chassis, powertrain, and structure: All of this needs to be thought through and developed, all of this must mesh perfectly together for the dream of winning the title in Australia.
This is where Covestro comes into play in the vehicle's development. The Aachen team had and continues to have many questions regarding the use of materials. They are a crucial factor in the quest for victory in the solar race through the Australian Outback. The components not only need to be lightweight, strong, and aerodynamic but also must withstand strong mechanical vibrations and extreme climatic conditions such as heat, humidity, and high UV radiation. Covestro has quite a lot to offer here: Highlights include chemically recycled polyurethane foams used in the seat. Recycled elastomers named Vulkollan® serve as damping elements between the battery and body, ensuring full functionality under maximum stress.
Additionally, Covestro materials can be found in the battery cell holders, outer shell, interior trim, headlights, turn signals, and in the paintwork of the solar race car.
Regardless of the outcome of the race, Team Sonnenwagen has done a great job in my opinion,”. “What these students from Aachen have achieved with the design of their solar car is a demonstration of innovative strength, team spirit, and determination. They deserve nothing but congratulations. And I am always delighted that we are able to support this extraordinary team with our innovative and sustainable technologies and our expertise.
Strong performance in the outback: Æthon finishes fourth
In recent years, Team Sonnenwagen has built up an impressive race record: European champions in 2022 at the iLumen European Solar Challenge in Zolder, winners of the Italian Solar Challenge 2022 in Imola, and second and third place at the iESC 2024 with the Covestro Photon and Covestro Adelie.
With the new Covestro Æthon, the team is continuing this success story and finished fourth in the 2025 Bridgestone World Solar Challenge in an international field of 37 teams from 18 countries.
After securing pole position in qualifying with a new team best time of 1:52.50 minutes, the Æthon proved itself impressively on the more than 3,000-kilometer route through the Australian outback. Heat, dust, gusts of wind, and strong vibrations placed the highest demands on the vehicle – and thus also on the materials used.
The success demonstrates how powerful modern high-performance plastics are in the mobility of tomorrow. At the same time, the race provides the Sonnenwagen team and Covestro with valuable insights for future vehicle concepts, material innovations, and recycling technologies. Together, both partners continue to work on pushing the boundaries of what is technically feasible – and taking sustainable mobility to the next level and “to the finish line.”
