Unidirectional Inertial Lockout

This console bin door has no latch in the closed position, but a undirectional inertial lockout feature was implemented to meet FMVSS 201. The lockout's inertial sensitivity is defined by part geometry, allowing it to be made of any material while maintaining the same inertial properties. A single injection-molded snap-in lever plus felt tape replaced multiple die-cast metal components, minimizing testing costs due to compliance the first time, increasing reliability, and saving 7.85 g and $0.84 USD costs vs. the previous metal option.

OEM/Vehicle Ford Motor Co. 2016 Lincoln MKC System Supplier International Automotive Components Group Material Processor West Michigan Molding, Inc.

Material Supplier Celanese Resin Celcon LW90-S2 POM

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

Drop-in TPO Chute in Seamless Leather FIP IP

This is industry's first use of a drop-in TPO passenger airbag chute in a seamless leather, foam-in-place system. Door, hinge, and frame are all integrally molded into the same patented TPO chute, providing faster deployment and saving approximately 0.7 lb and $1.25 USD direct and indirect costs per vehicle.

OEM/Vehicle Ford Motor Co. 2016 Ford Explorer System Supplier Eissmann Group Automotive Material Processor Faurecia

Material Supplier Mitsubishi Chemical America Resin Mitsubishi Chemical TT 860 TPO Tooling/Equipment Supplier Reko International Group

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

Energy-Absorbing Armrest

An open design with a flexible, yet durable cover replaced conventional molded slots or honeycombs in this injection-molded armrest, improving vertical load performance and side-impact energy absorption. In addition to boosting performance, durability was also increased 3.5 times on this police special vehicle.

OEM/Vehicle Ford Motor Co. 2015 Ford Explorer System Supplier Yanfeng USA Automotive Trim Systems Inc. Material Processor Yanfeng USA Automotive Trim Systems Inc.

Material Supplier MRC Polymers Resin PP Tooling/Equipment Supplier Yanfeng USA Automotive Trim Systems Inc.

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

Floor Rocker Reinforcement

An optimized MPPE/PA 6 honeycomb geometry in a plastic/metal hybrid proved to be a very efficient energy-absorbing crash-box structure in this floor rocker reinforcement. Not only is the component E-coat capable, but it is very easy to assemble into the vehicle's BIW. Since the plastic honeycomb is integrally attached to 2 steel flanges during injection molding, no structural adhesives are needed. The mixed-material solution took 1 kg of weight out of the BIW, saved approximately 10%, and contributed tooling savings vs. previous steel solutions.

OEM/Vehicle FCA US LLC 2015 Jeep Renegade System Supplier Proma Group Material Processor SABIC

Resin NORYL GTX 910 PPE/PA Tooling/Equipment Supplier Redstamp

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

Direct Fascia-Mounted Sensor

A flexible pedestrian-protection crash sensor bracket injection molded in plastic with an embedded metal stud is sonically welded directly to the fascia skin to decrease signal noise and improve response time of the deployable hood system. The flexibility of the design helps the bracket to conform to different fascia contours, allowing for a single bracket design to be used in multiple locations on the same vehicle, or across different vehicle lines. The final design saved 1 lb and $5 USD/vehicle and allows the hood to deploy faster for greater pedestrian safety.

OEM/Vehicle Ford Motor Co. 2015 Ford Mustang System Supplier MacLean-Fogg Co. & Ford Motor Co. Material Processor MacLean-Fogg Co.

Material Supplier LyondellBasell Resin Hifax 852X TPO Tooling/Equipment Supplier Industrial Automation LLC.

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

Door Bolster Tuned Safety Targets

After 40 revisions on CAE, this door bolster was improved to meet side-impact as well as vertical-load requirements without changing the airbag, adding energy-management beams in the door, or changing the structure of the sheet metal. No new secondary tooling was required and only minor Class A surface changes were needed.  The resulting part saved 2.6 lb, $1.87 USD in material costs, and reduced side-impact forces 400%. The patent-pending design took just 20 months to be implemented.

OEM/Vehicle Ford Motor Co. 2016 Ford Super Duty System Supplier Yanfeng USA Automotive Trim Systems Inc. Material Processor Yanfeng USA Automotive Trim Systems Inc.

Material Supplier LyondellBasell & Borealis AG Resin Pro-fax SG-702 PP Borealis WN100AI 10% TF PP Tooling/Equipment Supplier Hi-Tech Mold & Eng., Inc.

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

Door-Trim Switch Bezel

By combining a heated mold and a special stainless-steel cavity with extra cooling on the grained surface, it was possible to create the look of 2 parts (one in high-gloss piano black and one in a low-gloss grained surface) in a single tool while achieving impeccable fit and finish and craftsmanship.  This eliminated the need to mold multiple parts and/or paint, saved 200 g and $4 USD/vehicle, and eliminated the VOCs and cost of a painting operation.

OEM/Vehicle Ford Motor Co. 2016 Ford Edge System Supplier Yanfeng USA Automotive Trim Systems Inc. Material Processor Yanfeng USA Automotive Trim Systems Inc.

Material Supplier BASF Corp. Resin Ultramid A3L PA66 Tooling/Equipment Supplier Michael Tool & Mold (Windsor) Ltd.

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

A-Side Scoring in Seamless Leather FIP IP

For seamless-leather IP applications, positional tolerance between the leather scoring line and the underlayment PVC skin's scoring line was reduced 80% vs. conventional Class B weakening methods. This patent-pending method significantly improved deployment performance for seamless leather FIP systems, which led to substantial validation savings.

OEM/Vehicle Ford Motor Co. 2016 Ford Explorer System Supplier Eissmann Group Automotive Material Processor Faurecia

Material Supplier KEM ONE Resin Nakan DSY300/15 PVC Tooling/Equipment Supplier Fichtner & Schicht GmbH

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

2-Shot Selective Chrome & Paint Finish Panels

To meet program direction for a multi-colored finish panel within the same package space (without incremental space for attachments) meant a 2-shot selective chrome and paint solution in a single molded piece with similar materials was needed. In the first shot, PC/ABS is injected into a dual cavity tool on a rotary platen. In the second shot, a very-thin plateable ABS grade is overmolded.  Dip plating plus masking and painting offer numerous finish options with lower gloss over plating and MIC applications. The result achieves a very-good bond, has zero-margin gap, and no BSR issues. 

OEM/Vehicle Ford Motor Co. 2016 Ford Explorer System Supplier Summit Polymers, Inc. Material Processor Lawrence Automotive Interiors Ltd.

Material Supplier SABIC Resin CYCOLAC ABS CYCOLOY PC/ABS

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

IMX Instrument Panel

To eliminate scratches and a hard "plastic" feel, a 2-shot compression-injection soft IP was developed. The back-foamed TPO foil is compression-injected with the PP substrate, which in turn is integrally injection molded with the TPO passenger-side airbag door. All the work is done in a single tool. To increase foam softness and stability of the integral injection molding, the TRIZ method and design of experiments tools were used. The resulting part saves $10 USD/vehicle and reduces mass 300 g.

OEM/Vehicle Hyundai Motor Group 2014 Hyundai i20 System Supplier Hyundai-Mobis Material Processor HanilEhwa

Material Supplier Hanwha L&C Resin Multiflex 3202 TPO Tooling/Equipment Supplier Hyundai Motor Group

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

Tonneau Cover

Injection/compression molding was used to produce this lightweight (65 lb), thin-wall lockable tonneau cover, allowing a much smaller press to be used. Once molded, top and bottom halves, reinforcement bars and assembly clips are added and the two halves are vibration welded. One of industry's largest high-frequency vibration-welding machines is used to bond up to 70 in.2 of welded surface. The PP grade used was specifically formulated to reduce warpage and facilitate proper welding/assembly.

OEM/Vehicle Toyota Motor Corp. 2016 Toyota Tacoma System Supplier ASC Inc. Material Processor Nyloncraft Inc.

Material Supplier Asahi Kasei Plastics North America Resin Thermylene P6-30FM-0829 PP Tooling/Equipment Supplier Briadco Tool & Mould Inc.

For More Information See: http://www.plastics-car.com/FAQs/General-Plastics-Questions.html?css=print