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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