For the first time a working group of german universities developed an efficient, environmentally compatible and safe passenger car. The design of the UNI-CAR was specifically adjusted to the safety of persons outside the vehicle. Thus, for protecting pedestrians and drivers of two-wheeled vehicles, several of the bodywork components were primarily developed on the basis of polyurethane integral skin foam to cushion the impact of a person upon the car from outside. For instance, the car was given a reversibly deformable front end and a cushioned bonnet as well as cushioned window frames and roof edges, without impairing the design or aerodynamics of the vehicle. The report explanes the aspects of materials selection and vehicle design, the problems and experiences associated with the manufacture and application of these plastics components as well as test results.