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Wednesday, March 14, 2012

1-Piece Structural TPO Aero Rocker Molding



A patented, non-traditional injection molding process, where a chemical foaming agent is combined with TPO, was used to produce this rigid 1-piece structural component that met customer requirements while maintaining a Class A surface and lowering weight and part count vs. previous processes.  The innovation saved 2 parts and 3.86 lb / vehicle, resulting in a $7.6-MM USD direct cost savings and an additional $1.0-MM USD estimated indirect cost savings due to reduced part complexity and assembly-plant labor.



OEM/Vehicle
Ford Motor Co.
2012 Ford Edge SUV
System Supplier
ABC Group
Material Processor
ABC Group
Material Supplier
LyondellBasell Advanced Polyolefins USA, Inc.
Resin
Sequel TYC 852P TPO
Tooling/Equipment Supplier
Delta Tool 

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