First Publicly Accessible Airbag Systems

The first use of driver and front passenger airbags on mass-produced vehicles available for the general public was the 1974MY Oldsmobile® Toronado luxury 2-door hardtops. Together with safety belts, airbag systems are the cornerstone of passenger protection for front and side crashes.  Just in the U.S., the National Highway Transportation Safety Administration (NHTSA) estimates that the combination of seatbelts and airbags have saved more than 28,000 lives in frontal crashes since 1999.

OEM/Vehicle General Motors Co. 1974MY Oldsmobile Toronado System Supplier Multiple Material Processor Multiple

Material Supplier Multiple Resin Multiple

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

Vehicle Engineering Team Award (VETA)

Plastics and composites were key enablers for creating the new 2013MY SRT Viper supercar.  Not only did these materials contribute to greater occupant comfort, safety, and vehicle performance, but they directly lowered vehicle mass approximately 100 pounds (45 kilograms).  In fact, more than 50% of the vehicle's skin is composite. 

OEM/Vehicle Chrysler Group LLC 2013MY SRT Viper  System Supplier Multiple Material Processor Multiple

Material Supplier Multiple Resin Multiple

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

Energy-Absorbing Screw-Cap Cover

Integration of energy-absorbing features into a visual screw-cap cover on a headliner-mounted assist handle provides the possibility of eliminating headliner countermeasures inboard of the grab handles, saving $2-4 USD in cost avoidance.   The grab-handle systems it replaced exposed the functional features, creating a less aesthetically desirable appearance.

OEM/Vehicle Ford Motor Co. 2013MY Ford Fusion/MKZ System Supplier Grupo Antolin Ingenerria Material Processor NIFCO Products ESPANA

Material Supplier DuPont Performance Polymers Resin PA Tooling/Equipment Supplier NIFCO Products ESPANA

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

Portable Electric-Vehicle Charger

This charging system consists of 4 major components that, together, deliver a robust and reliable charge cycle for an electric vehicle.  The user-friendly system plugs into existing electrical infrastructure and provides multiple levels of safety for the user, the EV, and charging equipment.  It meets numerous Underwriters Laboratories (UL)  safety requirements, yet is robust and attractive enough for everyday use.

OEM/Vehicle General Motors Co. 2012MY Chevrolet Volt System Supplier Delphi Corp. Material Processor Delphi Corp.

Material Supplier SABIC Resin Valox PBT

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Electrical-System?css=print

Integrated Headlamp / Hood Bump-Stop Bracket

Hood bump stops, together with headlamps, provide stiff resistance to the hood structure when impacted, leading to high HIC values during pedestrian-protection testing.  Hood material, shape, and packaging space can also affect HIC performance.  Traditionally, the hood bump stop and headlamp attachment bracket are designed as separate components. However, a new integrated 1-piece plastic bracket combines the function of the hood bump stop and headlamp attachment and offers a more efficient way to meet new pending ped-pro requirements.  The injection-molded 30% GR-PP patented part is tunable for a wide range of breakaway load levels, can be used on other vehicles, reduces assembly complexity, and lowered HIC values by ~30%.

OEM/Vehicle Ford Motor Co. 2013MY Ford Fusion System Supplier Magna Exterior & Interior Material Processor Magna Exterior & Interior

Material Supplier Styron Resin PP Tooling/Equipment Supplier Advantage Mold Inc.

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

Front Bolster Assembly

This 1-piece PA 6/6 fascia bolster is tunable, thanks to stress initiators designed into the part to control energy absorption and breakage, enabling vehicle safety targets to be achieved without any body structure changes.  It led to exterior body craftsmanship improvements for fascia-to hood flushness (61%), gap (38%), parallelism (33%), and deflection (43%) while reducing OEM labor 50%, and saving 1.8 lb / 0.8 kg and $2.50 USD variable cost per vehicle.

OEM/Vehicle Ford Motor Co. 2013MY Ford Mustang System Supplier JCIM LLC Material Processor JCIM LLC

Material Supplier BASF Corp. Resin Ultramid A3WG7 35% Glass Filled PA6 GF PA Tooling/Equipment Supplier Toolplas Systems Inc.

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

Collapsible Cargo-Management System

An innovative cargo-management system / load floor was designed to maximize customer package space while making the battery accessible, protecting the battery cooling fan (which cannot support direct top loading), and reducing stackup risk to the HEV battery system during a high-speed rear impact.  The mineral-reinforced PA 6 design features legs and vertical walls that support load above the fan while rib structures provide perimeter strength, and the bin supports the load floor around the perimeter.  A door permits the battery to be disconnected during service and molded "steps" were designed to create fracture lines under compression during a rear impact to protect the battery.

OEM/Vehicle Ford Motor Co. 2013MY Ford C-Max System Supplier NYX, Inc. Material Processor NYX, Inc.

Material Supplier BASF Corp. Resin Ultramid B3M6 PA 6+ 30% mineral Tooling/Equipment Supplier Reko Manufacturing Group Inc.

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

Carbon Fiber Composite Roof Assembly

This carbon fiber composite roof assembly is a Class A part that is a key structural component of the vehicle.  Layup orientation and thickness were custom tuned to meet various structural requirements of both part and vehicle.  Complex layup of plies was enabled by a CAD-drive laser placement system, which directs the operator in positioning plies during layup of the prepreg kit.  Structural rigidity was increased vs. aluminum or SMC while weight was significantly reduced.

OEM/Vehicle Chrysler Group LLC 2013MY SRT Viper GTS System Supplier Plasan Carbon Composites Material Processor Plasan Carbon Composites

Material Supplier Toray Composites (America), Inc. & Umeco plc / Cytec Industries Resin G83C  T700S-24K carbon fiber Tooling/Equipment Supplier Windsor Mold

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

Sunroof Wind Deflector

This multi-material sunroof wind deflector is co-molded using rigid LFT-PP overmolded with a flexible styrenic-block copolymer TPE (TPE-s) using a 2-shot rotary press. Careful materials selection assured high rigidity, low moisture absorption, toughness, good aesthetics, and light weight for the LFT-PP grade, as well as good UV stability and a strong cohesive bond for the TPE grade.  By co-molding the part on 1 press, costs are reduced, there is less flash, secondary operations are eliminated, scrap is lowered, appearance is improved, warranty costs are reduced, and a more robust adhesion between materials is achieved.

OEM/Vehicle Ford Motor Co. 2011MY Focus C346 System Supplier Webasto Roof Systems, Inc. Material Processor Windsor Mold Group

Material Supplier Ticona Engineering Polymers Resin Celstran PP-GF40-03 LFT-PP-GF40

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Body-Exterior/Auto-Trim.html?css=print

Hybrid Rear Bumper Beam

This is the first hybrid (plastic / steel) rear bumper beam that can travel through the OEM E-coat process. An unfilled, crushable MPPE/PA honeycomb that is hot-plate welded to a base plate is used to pass all relevant test specifications.  The part also provides support and fixation for the rear bumper fascia, while reducing mass 1.5 kg / 3.3 lb and cost 10%.

OEM/Vehicle Fiat SpA 2011MY Fiat Panda System Supplier Ben Vautier Material Processor RT Technologies

Material Supplier SABIC Resin Noryl GTX 910 MPPE / PA Tooling/Equipment Supplier Redstamp

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Body-Exterior/Bumpers-Fascia-Systems.html?css=print

Direct Extrusion of Bulb Seal on Cowls

By directly extruding a bulb seal onto an air-inlet panel (cowl), the application's functional requirements are met and time-consuming manual installation of the seal is eliminated as a secondary operation.  An extrusion die, mounted to a flexible, heated hose and guided by a robot, quickly and efficiently lays down a TPV profile along the edge of the injection-molded substrate.  The fully automated process creates an easily tunable and functional seal that can be handled immediately after extrusion without need for post cure (as with thermoset rubber).  The operation is cost-effective, eliminates a secondary operation, maximizes sealing to the hood interface with excellent dimensional stability, reduces scrap, and provides high design freedom and process flexibility.

OEM/Vehicle Ford Motor Co. 2013MY Ford C-Max System Supplier Windsor Mold Group Material Processor Windsor Mold Group

Material Supplier ExxonMobil Chemical Resin Santoprene 121 50E500 TPV Tooling/Equipment Supplier Reis Extrusion GmbH

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Interior/Air-Ducts.html?css=print

Hidden Surface Front Seat Back Panel

Goals of this high-volume program were to enable thinner seat styling by reducing visual mass and volume of front seat back, permit trim to side airbag (SAB) interface, eliminating dependence of trim cover material to airbag deployment, allow mid-cycle changes to trim materials without having to retest airbag system, and facilitate assembly of airbag to seat. This was accomplished with an injection-molded neat PP substrate and SAB pocket that were vibration welded to allow the airbag to be mounted externally to the trim cover, and the trim cover to be attached to the back panel.

OEM/Vehicle Ford Motor Co. 2013MY Ford Fusion System Supplier Beach Mold & Tool, Inc Material Processor Beach Mold & Tool, Inc

Material Supplier LyondellBasell Industries Resin Pro-Fax SG 802-N PP Tooling/Equipment Supplier Beach Mold & Tool, Inc

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

B-Pillar Gas Assist Grab Handle

Gas-assist injection-molded PP was used to replace steel overmolded with PVC for a structural grab handle that assists occupant ingress/egress in second-row seats of this crew-cab pickup.  The part provides the structural performance and comparable haptics of the steel-reinforced handle it replaced without degradation due to allowable load forces.  It meets FMVSS 201 and Ford internal safety standards by integrating HIC countermeasures directly in the part.  This led to weight reduction of 1 lb/0.5 kg, a cost reduction of $1.30 USD, and a cycle-time reduction of 10% per handle while improving color and harmony and facilitating easy recycling.

OEM/Vehicle Ford Motor Co. 2012MY Ford F150 System Supplier Johnson Controls Material Processor Johnson Controls

Material Supplier LyondellBasell Industries Resin PP

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