Chrome Film Thermoformed Bumpers

This is the largest and thinnest chrome-film thermoformed TPO fascia to date.  It offers excellent impact resistance and gravelometer performance, is fully recyclable, and offers a lustrous chromed surface while eliminating hexavalent chromium chemicals.  The result is a lighter, less costly bumper cover that is more environmentally benign. Low tooling costs make this technology very attractive for quick-change transition parts at any production volume.

OEM/Vehicle Retro USA 2009 Limited Edition "Bullit" Mustang System Supplier Retro USA Material Processor Orion Plastics & Brentwood Industries Inc.

Material Supplier Mytex Polymers Inc. & Soliant LLC Resin MetaForm 7200 TPO Tooling/Equipment Supplier Castek

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

Transmission Sump Filter

This all-plastic assembly replaced crimped metal for a transmission sump filter.  Laser welding was used to rapidly and efficiently join the injection-molded components so there was no debris that could contaminate the filter media as can occur with spin or sonic welding.  The resin also allows for laser marking for easy traceability.

OEM/Vehicle General Motors Co. 2009 GM FWD Cars w / 6-Speed Transmissions System Supplier Filtran Ltd. Material Processor Filtran Ltd.

Material Supplier Entec Polymers, LLC Resin Hylon N1033HL PA 66

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

Powder-Coated Plastic Roof-Rack Cover

Conductive, powder-coatable MPPE/PA resin was used for this plastic roof-rack cover to ensure perfect color-match (metal-to-plastic) at lower cost vs. liquid paint. Not only were VOCs (from conventional paint) eliminated, but a 30% direct cost savings was also achieved.

OEM/Vehicle Skoda 2009 Yeti System Supplier ACL Material Processor MSSL

Material Supplier SABIC Innovative Plastics Resin Noryl GTX 674PC PPO/PA Tooling/Equipment Supplier MSSL

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

Ni-MH Battery Cell Enclosure

This is the first use of engine coolant as a cell-cooling medium for Ni-MH battery cells for a hybrid cross-over utility vehicle.  A special PPE/PE copolymer provides lightweight stiffness, creep resistance, and seals out moisture for this battery cell enclosure while providing resistance to alkali battery and coolant chemicals.  The high-productivity resin provided excellent molding productivity in thin walls.  A special film-insert molding process and secondary welding technology were also developed for this application. The unit saves an estimated 2.3 kg vs. alternative resins considered for the application.

OEM/Vehicle BMW 2010 ActiveHybrid X6 System Supplier Cobasys LLC Material Processor PM Plastics Co.

Material Supplier AsahiKasei Plastics Resin Xyron EV-103 PPE + PP Tooling/Equipment Supplier Arlen Tool Co. Ltd.

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Engine-Components

Lumbar Seat-Adjuster Comfort Mat

Low-VOC acetal copolymer was used for this structural / frictional component, reducing cabin odor / fogging for improved passenger comfort.  Conventional resins did not meet the new VDA 275 performance targets for low VOCs.

OEM/Vehicle Chrysler Group LLC 2011 Jeep Grand Cherokee System Supplier Brose North America Material Processor Axiom Products

Material Supplier AsahiKasei Plastics Resin Tenac-C Z4520 POM Tooling/Equipment Supplier Axiom Products

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

Dual-Lens Cupholder Light

In this next-generation interior-lighting application, a 1-piece design integrates primary illumination surface and show-surface lens for improved craftsmanship, 10% weight savings, and $0.35 USD cost savings vs. previous 2-piece lens designs.  The design also reduced assembly costs and lowered warranty issues.

OEM/Vehicle Ford Motor Co. 2011 Ford Explorer System Supplier Chicago Miniature Lighting, LLC Material Processor Chicago Miniature Lighting, LLC

Material Supplier Ashland Resin Cyro Acrylite 8N-123-000 PMMA Tooling/Equipment Supplier Global Management & Sales Group

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

Cam Cover with Integrated Variable-Valve Timing

This is the first time that a plastic surface has been used for a cam variable-valve timing cover.  Holding a positional tolerance of 0.5 mm and required to pass 100% inspection, the application required development of a special workstation with laser and optical measurement tools to verify dimensional compliance.  High-flow 35%-glass-reinforced PA 6/6 was injection molded for this application and replaced machined die-cast aluminum while saving 2,200 g and 25% direct material costs.

OEM/Vehicle Chrysler Group LLC 2011 Jeep Cherokee System Supplier Bruss NA Material Processor Bruss NA

Material Supplier BASF Corp. Resin Ultramid A3WG7 HP BK20560 PA66 35% GF Tooling/Equipment Supplier Active Burgess

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Engine-Components

Energy Absorbing Module

The injection-molded Safe-TEC module’s design flexibility provides a unique safety-integration point, since stiffness can be tuned multi-axially to optimize energy-absorption requirements for occupants ranging from 5th to 50th percentile – all in a single component.  The module’s design can be integrated with existing injection-molded components to reduce weight, investment, and complexity and to significantly reduce part count.  Mass was reduced 0.91 kg/vehicle and significant cost-savings were achieved.  The pelvic version saves $3.20 USD for pickups and $2.77 USD for SUVs, while the armrest version saves $3.30-$3.50 USD / vehicle.

OEM/Vehicle General Motors Co. 2010 Chevy Silverado, Suburban, Tahoe & Avalanche, GMC Sierra & Yukon, & Cadillac Escalade System Supplier International Automotive Components Material Processor International Automotive Components

Material Supplier LyondellBasell & Formosa Plastics Resin Pro-fax SG802N PP Formelene 6535N PP Tooling/Equipment Supplier International Automotive Components

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

Low Gloss Coatings on TPO Hood Molding

This injection-molding application features a new type of hood molding – on the rear of the hood with a special low-gloss coating – to enable a particular look desired by the styling studio.  A TPO was selected as the base resin because of its excellent dimensional stability to limit cross-car growth.  Then special low-gloss base-coat/clear-coat paint replaced a low-gloss mono-coat system to create an impactful styling feature.

OEM/Vehicle General Motors Co. 2011 Chevrolet Volt System Supplier AP Plasman Material Processor AP Plasman

Material Supplier LyondellBasell Resin Sequel 1828 TPO

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

Electronic Throttle-Control Actuator

This electronic throttle-control actuator meets or exceeds all USCAR global standards and focused on mass reduction.  The unit makes use of injection-molded PA 4/6 and PBT resins to produce 7 innovative plastic components:  an ultra-thin-wall carbon fiber-reinforced PA 4/6 bushing, ultra-high-strength gears with outstanding dimensional stability, high-temperature electric motor brush card, and a uniquely designed cover / cap combination.  In total, 43 g of weight were saved on this program vs. previous designs.

OEM/Vehicle General Motors Co. 2010 All (Global) System Supplier Continental Automotive Material Processor DSM Engineering Plastics

Resin Stanyl PA46 Arnite PBT

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

Charge-Port-Door Housing Assembly

To give the new Chevrolet Volt some extra sizzle, a plastics-intensive assembly was used to convert a conventional fuel-door housing to a charge-port-door system that protects the electric vehicle’s charge receptacle from dust and water, while adding decorative chrome bezels, an actuated door with a damped system, and a double-lip-seal design.  Multiple materials and injection molding were selected for the complete assembly.

OEM/Vehicle General Motors Co. 2011 Chevrolet Volt System Supplier ITW Deltar Fuel Systems Material Processor ITW Deltar Fuel Systems

Material Supplier BASF, SABIC, DSM, RheTech Resin PA-GF50, PA66+PPE, ABS+PC, EPDM-TPE, PP-GF20 Tooling/Equipment Supplier Flowline Tool & Mold Inc. & Industrial Tooling

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

Self Reinforced Airbag Door System

This is the auto industry’s first airbag door system that integrates an all-PP construction, (PP-fiber-reinforced PP).  As such, it is fully recyclable and does not require typical post-mold scoring / weakening of the door flap.  The injection-molded door system is the lightest, least-expensive system solution, since additional components and post-mold operations (to enable the door flap to open / hinge) are eliminated.  Multi-zone temperature control of the mold was required, as was use of a vacuum-holding system for the fabric insert.  The program also required development of a specialized fiber-reinforced material to facilitate overmolding and subsequent adhesion. The resulting system reduced weight between 30% & 300% weight vs. competitive systems and saved approximately $5 USD/part vs. welded systems.  Additional indirect savings of approximately 5% were also accrued, and production scrap is 100% recyclable.

OEM/Vehicle PSA Citroën 2008 Citroën C5 System Supplier Visteon Corp. Material Processor Visteon Corp.

Material Supplier LyondellBasell & Propex Fabrics Resin PP

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