Integrated Front End Module System

Compression-molded SMC was used on the first North American implementation of integrated front-end module (FEM) systems for cost, weight, and functional performance. Switching from metals allowed for significant parts consolidation, eliminating 22 major subcomponents and 27 fasteners/vehicle plus related design drawings/CAE models, stamping tools, gauges, fixtures, plus purchasing and logistical tasks. The single-piece 'ready-to-install' structural carrier with self-locating fasteners improved assembly operations, provided an 'open architecture' for powertrain installation, eliminated 9 line locations and 15 work-cell locations, reduced weight 22% and costs 14%, while boosting quality (R/1000) 22% vs. previous designs. Additional benefits included improved serviceability and documented reductions in collision insurance costs while meeting all safety requirements.

OEM/Vehicle Ford Motor Co. 1996 Ford Taurus & Mercury Sable sedans System Supplier Toledo Mold & Die Material Processor Budd Plastics Division

Material Supplier Budd Plastics Division Resin SMC

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

Collapsible Armrest for Side Impact

This injection-molded armrest has been specially designed to maintain full integrity for NVH, comfort, aesthetics, and durability during normal service life yet to detach and collapse during lateral loading from a side impact. Using PVC and ABS materials, the design features a single-piece insert and armrest with molded-in slots that create a slip plane that is rigid enough for normal use but creates a failure path that provides for reduced occupant injury numbers. It also reduces material usage and costs 25% and a 15% reduction in assembly costs.

OEM/Vehicle Ford Motor Co. 2013 Ford Edge & Lincoln MKX CUVs System Supplier Johnson Controls Inc. Material Processor Johnson Controls Inc.

Material Supplier Styron Resin Magnum 3325MT ABS Tooling/Equipment Supplier Toolplas Systems Inc.

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

Side Airbag Cover

Replacing a conventional metal can and plastic cover, this is the first time that an insert-molded bracket/cover assembly has been designed to be both the mounting surface for the seat side airbag (SAB) as well as integral to the performance and cosmetic function of the cover. This unique design answered the challenge of meeting styling studio requests for a thin seat appearance, but providing packaging space for increasingly large side airbags, which now typically protect occupants from chest to pelvis.  A cantilevered metal bracket allows for efficient assembly at the airbag supplier, reducing part counts typically required for a Class A side airbag module and saving 300 g of weight.  Extensive filling and tooling development was used to ensure proper bracket encapsulation by the tough TPO resin, which maintains a Class A appearance during normal use but delivers proper airbag deployment in a side impact event.  The design also virtually eliminates craftsmanship fit concerns that can be an issue with conventional "can & cover" SAB designs.

OEM/Vehicle Ford Motor Co. 2013 Ford Fusion midsize sedan System Supplier Autoliv Inc. Material Processor Atlantic Precision Products

Material Supplier Mitsubishi Resin TT914 CNP TPO Tooling/Equipment Supplier Great Lakes Mold & Engineering

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

Fabric for Passenger Airbag Cushion

PET replaces PA fibers in the fabric of this passenger-airbag cushion (PAB) system.  This is the first time that PET has been used with hot-gas (pyrotechnic) inflators on PABs in North America.  The resulting polyester fabric met all validation requirements and performs just as well and as nylon fabrics but at 25% lower fabric costs.

OEM/Vehicle Ford Motor Co. 2014 Explorer SUV / Taurus sedan System Supplier Key Safety Systems Material Processor Key Safety Systems

Material Supplier GST AutoLeather Resin PET

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

3.5L/3.7L V6 Integrated Coolant Cross-Over

This integrated composite coolant cross-over tube eliminates corrosion associated with aggressive long-life coolants (LLCs) while taking 1 lb of weight and $1 USD cost out of each engine, thereby improving service life, fuel economy, and CO2 emissions while saving money. Previous designs using overmolded brazed metal tubing was replaced by tubing injection molded of 35% GR PPA. Each molded tube is subsequently inserted into a second tool and overmolded with 30% GR PA 6 to form the rest of the intake manifold. Significant structural design work was performed to ensure the hollow PPA tube could survive the pressures of overmolding and special mold-cavity pressure-sensing technology developed by RJG helps prevent damage during the process.  The PPA material was already proven safe with LLC coolants, eliminating corrosion concerns while reducing development costs, and the combined system is now easier to recycle. Further, the intake-manifold supplier now makes its own cross-over tubes, reducing cost variations due to metals-market fluctuations.

OEM/Vehicle Ford Motor Co. 2013 Ford Taurus, Flex, Edge, & Explorer & Lincoln MKZ, MKS, MKX, MKT vehicles System Supplier ITW Tomco Material Processor ITW Tomco

Material Supplier DuPont Performance Polymers Resin Zytel® HTN 51G35HSLR PPA & PA 6  Tooling/Equipment Supplier Luttmann Mold

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

Lightweight Seat Pan

In this seat pan, stamped steel is replaced by thermoplastic composite, which combines both discontinuous and continuous fiberglass reinforcement in a PA 6 matrix.  The award-winning design features 18 adjustment options to more comfortably fit drivers or passengers. It meets all required safety requirements while improving crash and long-term fatigue performance, yet reduces mass 45% as well as wall thickness (increasing packaging space) without any cost increase.  The part's design was extensively analyzed via a proprietary simulation tool, UltrasimÒ, increasing confidence in the ability to accurately predict behavior of continuously reinforced thermoplastic composites.  The part is produced in a hybrid injection-molding process that combines robotic handling of the pre-cut preimpregnated continuous-fiber insert and an infrared heater inside the injection molding tool that preheats and pre-forms the cold sheet prior to tool closure and overmolding with impact-modified, discontinuous short glass/PA 6, which is used to form ribs, edges, and other geometry that long fibers cannot fill.

OEM/Vehicle General Motors Co. 2013 Opel Astra OPC sports sedan System Supplier SeaTcon AG Material Processor Reinart

Material Supplier BASF Resin Ultramid B3S & B3ZG8 PA6

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

Pressure Press Technology

This is the first production use of a new rapid out-of-autoclave production process for carbon fiber-reinforced composites. It produces parts with comparable mechanical properties and better aesthetics (requiring less post-mold finishing) far faster than the traditional autoclave (in 17 vs. 150 min). This significantly reduces costs and makes carbon composites practical and affordable for the first time for medium-volume production. Key to this significant technology breakthrough was R&D characterization of the autoclave cure cycle and resin curing dynamics, which led to several patent filings, a 66% reduction in cycle time, a 30% reduction in direct part costs, and a 75% reduction in the cost of process consumables. Additionally, thanks to rapid temperature ramp up and cool down, and isothermal processing, traditional exothermic cure reaction is avoided, eliminating the need for nitrogen blanketing and release of volatiles. The specially designed pressure press controls the process. Nickel-vapor-deposition (NVD) tooling with embedded hot-oil heating/cooling lines moves heat quickly through the Z-axis for rapid curing. A reusable silicone rubber canopy (good for 400-500 parts) replaces the cost and mess of traditional bagging supplies. Since parts exit with more consistent surfaces, 35% labor is reduced in finishing operations.

OEM/Vehicle General Motors Co. 2014 Corvette Stingray sports car System Supplier Globe Machine Manufacturing Co. Material Processor Plasan Carbon Composites

Material Supplier Toray North America Resin Toray  Epoxy Tooling/Equipment Supplier Weber Manufacturing Technologies Inc.

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

Cup-Holder Plug

Dual-shot ABS and PP+EPDM overmolding are used to add user flexibility for console cupholders in this application. Designed to fit existing packaging space with a friction interface, the injection-molded plug adds stability for beverage containers and can be removed to provide a well for smaller beverage containers or other items.  Quality is improved, and customer satisfaction increased with the additional storage options and greater utility of the floor console this part provides.

OEM/Vehicle Ford Motor Co. 2014 Escape SUV System Supplier International Automotive Components Group Material Processor International Automotive Components Group

Resin ABS & PP Tooling/Equipment Supplier Everwill Industrial Limited

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

PHEV Battery Covers

These EV battery covers help provide greater trunk-storage volumes despite the presence of large battery packs while protecting those batteries and providing easy access to the fuse box from the second row of the vehicle. Self-integrated attachment features are used where there is no room for conventional attachments, helping provide a clean appearance. Cold compression molding is used to shape carpet materials, while injection molding is used to form plastic components. By combining tooling for multiple carpet and plastic parts, cycle times, materials handling, and labor are reduced and significant tooling savings are achieved.

OEM/Vehicle Ford Motor Co. 2013 Fusion midsize sedan System Supplier Autoneum Holding AG Material Processor Janesville Acoustics

Material Supplier Washington Penn Plastic Co., Resin PP & PET Tooling/Equipment Supplier RCO

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Chassis-Design-NVH-Performance/Brakes.html

High-Heat Turbo EGR Sleeve

This heat shield is integrated into the air-intake manifold inlet for high air-temperature applications like diesels.  In this area of the manifold, hot exhaust gas (EGR) is mixed with ambient-temp (fresh) air without failure of adjacent components.  The plastic heat shield offers several improvements vs. previous systems including greater design flexibility (molded-in vs. machined geometry); improved air/EGR mixing (thanks to molded features, which increase turbulence); 50% weight savings; enhanced component durability; and inherent corrosion resistance. A special heat-stabilized grade of 35% GR PA 6/6 is injection molded for the sleeve, replacing roll-formed aluminum and readily withstanding the continuous-service temperature of 220C and peak temperature of 240C. The application was cost neutral but reduced mass by 50%.

OEM/Vehicle Daimler/Mercedes 2013 I-4 turbo diesel engines System Supplier Montaplast GmbH Material Processor Montaplast GmbH

Material Supplier BASF Resin Ultramid D3G7 PA66

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