First Plastic Radiator End Tank

As one of the first major underhood applications for engineering plastics, the radiator end cap broke ground for many future engine-compartment applications. Objective for converting the application from aluminum to nylon were parts integration and cost reduction, weight reduction, and equal or better performance. 

OEM/Vehicle 1982 Ford® Escort® / Mercury® Lynx ®  compact cars by Ford Motor Co.  System Supplier Ford Plastics Product Division  Material Processor Hoover Universal

Material Supplier DuPont Automotive  Resin Zytel® glass-reinforced nylon 6/6

For More Information See: http://www.plastics-car.com/plasticfueltanks

Automated Wrap Floor Console

This process is an automated edge-wrapping technology for interior trim applications.  The unique bonding process involves heat and pressure used in conjunction with automated edge wrap tooling and yields improved fit and finish at reduced cost.

OEM/Vehicle 2008 Cadillac ® STS  sedan by General Motors  System Supplier Dakkota Systems Material Processor Continental Plastics Co.

Material Supplier Dow Automotive Resin Magnum ® 975P High Heat ABS Tooling/Equipment Supplier ASI

For More Information See: http://www.plastics-car.com/autointerior?css=print

Seat Energy Arm Rest

This armrest offers part integration and consolidation, reducing component counts from 26 to 8 parts, while offering enhanced aesthetics and ergonomics over previous product offering.   The new arm can be configured for three different option levels, using common components. 

OEM/Vehicle 2005  Commercial Buses System Supplier American Seating Material Processor MACK Molding Co.

Material Supplier BASF Corp. Resin Ultramid ® SEG7 PA 6 Tooling/Equipment Supplier MSI Mold Builders

For More Information See: http://www.plastics-car.com/Upholstery

Cut and Sew IP Top Pad

Cut & Sew PUR was laminated to an injection-molded LFT-PP retainer, then coupled with an innovative scoring technology to provide for seamless passenger airbag deployment while improving styling flexibility and enhancing appearance on this instrument panel. Cut & Sew PUR is a cost-effective solution for vehicle builds under 100,000 units, offering weight and cost savings, improved NVH, and the option for stitching and 2-tone colors to enhance perceptions of craftsmanship.

OEM/Vehicle 2008 Cadillac CTS ® sedan by Chrysler LLC  System Supplier Dräexlmaier Automotive Material Processor Dräexlmaier Automotive

Material Supplier Benecke & Ticona Engineering Polymers Resin Benova ® PU Celstran ® 30% LGF PP Tooling/Equipment Supplier HS Die

For More Information See: http://www.plastics-car.com/InteriorComponents

Pressure Formed IP Top Pad

This top pad is the largest known component to use the in-mold graining pressure forming process. Replacing a 3-step spray-adhesive / injection molding / PUR back foaming process, the product is produced in a 2-shot process that yields crisp radii and uniform grain with no stretch or loss of graining as seen in traditional vacuum forming. As produced, the part is 45 g lighter, 35% less costly, and capital investment was reduced 40% vs. traditional in-mold graining / foam-in-place operations.  

OEM/Vehicle 2006 Chrysler ® Sebring ® mid-size car by Chrysler LLC  System Supplier Faurecia Interior Systems Material Processor Pearl

Material Supplier O'Sullivan Resin PP 20% talc Tooling/Equipment Supplier KTX America / Kyowa

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Interior

Front Grille Molding

This is the first use of the Vacuum Injection Compression (VIC) process to produce such a part. The process provided the ability to pre-form, inject, and compression mold a Class A part edge-wrapped with a decorative film in a single-step process.  Use of VIC eliminated the need for performing, requires no major trimming, and reduces the need for part handling, auxiliary equipment, additional labor, floor space, and the need for paint.

OEM/Vehicle 2006 Mitsubishi FK Series trucks by Mitsubishi Motors System Supplier Sakae Riken Material Processor Sakae Riken

Material Supplier A. Schulman Invision Inc. Resin Invision ® CX Ionomer decorative film

For More Information See: http://www.plastics-car.com/bumpers

Front End Carrier

This is the first direct-long fiber thermoplastic (D-LFT) composite front-end carrier compounded with a twin- instead of single-screw extruder during the inline compounding (ILC) portion of the process.  ILC provides cost and weight savings vs. conventional injection and GMT composites, while also eliminating many secondary operations.

OEM/Vehicle 2007 Volkswagen® Golf ® / Bora ® / Jetta ®  cars by Volkswagen AG System Supplier Aksys de Mexico Material Processor Aksys de Mexico

Material Supplier Basell Polyolefins & Owens Corning Resin PP-LGF Inline Compound

For More Information See: http://www.plastics-car.com/structure

Electric Water Valve Assembly

This is the first single-package, multi-function, under hood, water-valve assembly that uses over molded joints to delivery better heat and AC performance.  System provided 58% less pressure drop, 42% less internal leakage, 33% higher flow, and 17% less external leakage, all at 40% lower weight and 15% lower costs.

OEM/Vehicle 2005 Nissan® Titan ® pickup / Armada®  SUV / Quest ® minivan by Nissan Motor Co. System Supplier Cooper-Standard Automotive Material Processor Klum

Material Supplier DuPont Automotive Resin Zytel ® HTN 51G35 HSLR PPA Tooling/Equipment Supplier Klum

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains/Transmissions.html?css=print

Transmission Thermal Valve Assembly

This is the first transmission by-pass valve with plastic poppet utilizing a patented, overmolded metal-to-plastic joint, which eliminates costly fittings and components, metal crimping, and welding processes.  The application produced a 50% weight and 30% cost savings, while improving performance and reducing leaks.

OEM/Vehicle 2006 Nissan® Sentra® compact car by Nissan Motor Co. System Supplier Cooper-Standard Automotive Material Processor Calico

Material Supplier DuPont Automotive Resin Zytel ® HTN 51G35 HSLR PPA Tooling/Equipment Supplier Lutman Precision Mold

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains/Transmissions.html

Integrated Transmission Baffle / Seal Lip

This is the first-ever single-materal design for an integrated transmission baffle/lip seal.  The GM patent-pending design eliminates oil aeration for improved clutch durability to 200,000 miles, provides 50% increase in oil life, improves pump performance 45%, and offers easier assembly and provides smoother shift performance.

OEM/Vehicle 2008 Chevrolet® Malibu® / GM Daewoo® Tosca® / Buick ® LaCrosse® China sedans by General Motors System Supplier Chunil Engineering Material Processor Chunil Engineering

Material Supplier DuPont Automotive Resin Hytrel ® 7246 TPC/ET Tooling/Equipment Supplier Chunil Engineering

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains/Transmissions.html

Electronic Throttle Control Module

This is the first plastic ETC housing, which replaces machined cast aluminum at mass savings of 28% and costs savings of 18%, while also reducing warranty costs and potential for ice freeze-up and potential throttle blade stick. A special zero-shrink BMC grade was used and the units tight concentricity better controls air flow at idle.

OEM/Vehicle 2007 Chrysler ® Pacifica ® cross-over vehicle by Chrysler LLC  System Supplier Bosch Material Processor Christophery

Material Supplier BMC Inc. Resin TetraDUR BMC TD 455 BMC thermoset polyester Tooling/Equipment Supplier Christophery

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains