Two Shot Interior Decoration Bezel

This unique 3-D decorative effect was achieved with 2K 'reverse' injection molding (1st shot tinted PC) with overmolding of grained surface with 2nd shot (self colored pigmented ABS). This is the first time this process was used to achieve the 3-D visual effect (color and texture) for a part of this size and geometry. A 30% cost save was achieved vs IMD/IML/high gloss painting and there was a 20% scrap reduction vs conventional 2-layer high gloss piano black appearance.

OEM/Vehicle Ford Motor Company 2018 Ford Fiesta System Supplier Faurecia Interior Systems Material Processor    Faurecia Interior Systems

Material Supplier Lotte Advanced Materials Resin INFINO LT1220 PC Starex LX0760 ABS Tooling/Equipment Supplier JP Grosfilley SAS

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

Squeak Resistant IP Cluster Bezel

This IP cluster was molded with a new, patented low gloss ABS resin that provides parts with a markedly lower coefficient of friction that eliminates squeak and “stick/slip” noises caused by interior components in a vehicle. 22 pieces of felt, 16 Mylar tapes and grease were eliminated in assembly resulting in cost savings of $1.62 per vehicle. There are 9 commercialized applications in North America resulting in $4 Million annual savings. This new material offers "no squeak" properties, drop in usage (replaces general purpose ABS without need for tooling modifications), high flow for larger more difficult to mold parts, and is not additive based. Low gloss appearance eliminates need for painting.

OEM/Vehicle Ford Motor Company 2016 Ford Mustang System Supplier Summit Polymers Material Processor Summit Polymers

Material Supplier Techno Polymer America Resin HUSHLLOY HS301 ABS

For More Information See: http://www.plastics-car.com/Automotive-Group/Sponsored-Projects-and-Industry-Issues

Nacelle Cover

A unique soft touch and feel was achieved for this interior application, while eliminating painting (and its associated costs and environmental impact). A unique recipe with a specially -developed glass fiber and PP combination, delivering equivalent performance of painted ABS, enabled a 30% cost savings by eliminating painting. Additional cost avoidance is possible with a reduction in overall rejections that may come from use of ABS.

OEM/Vehicle Tata Motors Limited 2018 Tata Tiago System Supplier Tata Auto Components Material Processor    Abhijeet Tool

Material Supplier SABIC Resin S3625 PP Tooling/Equipment Supplier Abhijeet Tool

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

Cargo Management Deployable Shelf

This first time use of a multi-functional cargo management system in an SUV provides the customer with dynamic storage options in the rear of the vehicle. It enables the use of the full height of the cargo environment as well as assisting in solving the common customer complaint of items falling out the rear of the vehicle. The system bins, components and actuation linkages are injection molded using various PP and ABS materials to meet new appearance and load requirements.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition/Lincoln Navigator System Supplier Valley Enterprises Material Processor    Valley Enterprises

Material Supplier Chase Plastics Resin PPH5TF2 PP & HI121 ABS Tooling/Equipment Supplier Reliable & Reasonable Tool Service LLC Buiter Tool & Die, Inc.

For More Information See: http://www.plastics-car.com/Plastics_101/QuizzesExams/Answers

Real Wood Interior Door Garnish Using Natural Cork

This is the first real wood film and parts technology using natural cork. It is eco-friendly not requiring cutting down trees (cork is harvested from the bark of living cork oak trees every ten years). It is more costcompetitive than conventional wood parts because of its simple structure and manufacturing process. Conventional wood parts are a multilayered structure using several layers of wood veneer and require 20 steps of complex molding and machining including milling. Cork wood film is made with lamination equipment and parts are processed via insert injection molding. A 24% weight and a 65% cost savings is achieved compared to wood. Cork’s unique honeycomb-structure offers elasticity, insulation and sound proofing.

OEM/Vehicle Hyundai Motor Company 2017 Grandeur Hybrid System Supplier Seoyon E-Hwa Interior Systems Material Processor    Seoyon E-Hwa Interior Systems

Material Supplier L & J Resin ABS Tooling/Equipment Supplier Seoyon E-Hwa Interior Systems

For More Information See: http://www.plastics-car.com/Plastics_101/QuizzesExams

Rear Quarter Window

Global industry's largest-ever (1200 x 450 mm) 2-component polycarbonate rear quarter window(RQW) on a production vehicle is 40% lighter (3kg lighter) and substantially more impact resistant vs. comparable RQW in glass. It also features design elements that cannot be achieved with glass, contributing to the more innovative exterior of the new-generation GL8.

OEM/Vehicle SAIC General Motors (SGM) 2017 Buick GL8 System Supplier Shentong Material Processor    Shentong

Material Supplier SABIC Resin Lexan GLX143 PC Cycoloy XCM830 PC/ABS Tooling/Equipment Supplier Inglass

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

Functional Spoiler Stanchion

Thermoplastic (ABS+PC) replaced metal to injection mold this spoiler stanchion enabling stylish, aerodynamics and an 86% weight savings while meeting strength/stiffness requirements. An innovative attachment scheme, including long bolts and compression limiters designed to attach the stanchions to the spoiler and to the vehicle without exposing the fasteners, was designed. Unique core out slides in the tool were created to enable the hollow stanchion design.

OEM/Vehicle General Motors 2018 Chevrolet Camaro ZL1 1LE System Supplier Transglobal Material Processor    Proper Tooling

Material Supplier Trinseo Resin Pulse 2000EZ PC/ABS Tooling/Equipment Supplier Proper Tooling

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

A/C Register Chrome Vane Cap

Chrome-plated ABS vane caps with a contoured edge create unique styling and a new decorative finish to A/C register vanes without jeopardizing vane surface appearance. An automated process is used to apply adhesive bonding material to the vane cap and then assemble the vane to the GR-PBT vane body with zero-gap margins for excellent fit & finish. The process eliminates appearance defects due to mechanical locks on the vane body and permits parts to be handled within 20 seconds.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Summit Polymers, Inc. Material Processor    Summit Polymers, Inc.

Material Supplier Samsung Group / Toyobo Resin MP-0160R ABS Vylopet EMC-450 PBT Tooling/Equipment Supplier Isen Tooling & Engineering Co., Ltd. Sunway Automotive

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

Rhapsody Blue MIC Vehicle Environment

Project goals were to achieve a unique MIC color space that looks luxurious but appeals to today's generation. It involved using the first transparent pigment-based interior color deliverable across 76 base resins for the vehicle interior. Once the color was mastered, early attempts showed it was prone to metamerism with a red/green directional hue shift. Numerous attempts to achieve color consistency bidirectionally with standard pigment adjustments did not solve the problem. Finally, the color was remastered using a non-TIO2 system that did not exhibit hue shift, eliminating the need to paint and creating a calming, cool color environment.

OEM/Vehicle Ford Motor Co. 2016 Lincoln Continental System Supplier Americhem Inc. Material Processor    Many

Material Supplier Americhem Inc. Resin PP,TPO, ABS,PA, POM Tooling/Equipment Supplier Many

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

New PC/ABS for Exterior Applications

Development of new filler technology with very-low CLTE improved dimensional stability and reduced gap sizes for exterior PC/ABS parts, helping improve fit & finish. High gloss and enhanced paint adhesion makes the material an excellent choice for painted applications. The new grade also is lower density (10%) for lighter lower-cost parts, provides excellent impact strength for better durability, and has improved dimensional stability to reduce warpage. And because MFI is increased, parts can be molded faster and in thinner walls. This allowed the new material to replace aluminum at half the weight and 40% cost reduction (excluding tooling).

OEM/Vehicle General Motors Co. 2016 Opel Astra Sports Tourer System Supplier General Motors Europe Material Processor    SRG Global

Material Supplier Trinseo LLC Resin PULSE XT9215 PC/ABS Tooling/Equipment Supplier Socem / SRG Global

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

Biomass-based Polyester Blend

The goals of this project were to develop a high-biomass-content thermoplastic polyester blend for window panels and steering-wheel bezels using biomass-based PETG -- reportedly the first application in the world.  The optimized PETG/ABS composition was used to replace a PC/ABS blend. Benefits include a 57% reduction in carbon emissions (145 tons/year), an 88% reduction in VOCs, and a significant increase in molded part chemical resistance. By weight, the biomass content is 25% and by C14, the biomass content is 14%.

OEM/Vehicle Hyundai Motor Group 2015 IONIQ System Supplier Seoyon E-Hwa Interior Systems Manufacturing Material Processor    Seoyon E-Hwa Interior Systems Manufacturing

Material Supplier SK Chemicals Resin PETG/ABS SKYTRA Bio Polyester

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

Outer Handle

This application is industry's first belt-integrated, outside door handle with switch activation to open both front and rear doors. The slender, minimalist, all-plastic, high-luster chrome-finish handle provides effortless operation, luxury feel, and quiet operation. The injection molded PC/ABS part with integrated zinc casting also features an e-handle with power-release switch to deliver a sleek, uninterrupted form that reduces mass 20% and cost 35% vs. conventional bond-on-bracket designs.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier ADAC Automotive Material Processor    ADAC Automotive

Material Supplier SABIC Resin Cycoloy C1200HF PC/ABS Tooling/Equipment Supplier Xinpoint

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Chassis-Design-NVH-Performance/Suspension.html?css=print

Quad-Barrel Convertible Cupholder

This console design converts from 2 cupholders plus a bin to 4 cupholders with the help of a patented slider tray assembly for greater user flexibility without the need to remove and stow components when not in use. The design of the injection molded PC/ABS cupholders accommodates beverage containers ranging from small coffee cups and water bottles to large all-day beverage containers while reducing weight 70% vs. the outgoing model and lowering costs $3 USD depending on content replaced.

OEM/Vehicle Ford Motor Co. 2017 Ford Super Duty System Supplier Summit Polymers, Inc. Material Processor    Summit Polymers, Inc.

Material Supplier SABIC Resin Cycolac XCY620 PC/ABS

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

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

Blow-Molded Spoiler Assembly

This blow-molded spoiler features a complex triangular-shaped design and 1-piece construction while maintaining uniform wall thickness and product integrity. Achieving the complex deep-draw features required a unique 3-piece tool including a large slide that extends the entire rear edge of the mold cavity.  Timed slide operations enabled the parison to expand with minimal stretch, and laser venting improved air evacuation for wall-thickness control. The final part meets aggressive styling objectives at 10% cost and 20% weight savings vs. conventional blow molding.

OEM/Vehicle General Motors Co. 2016 Cadillac ATS V Series System Supplier Metelix Products, Inc. Material Processor Metelix Products, Inc.

Material Supplier Trinseo Resin Magnum 1250BG ABS Tooling/Equipment Supplier Metelix Products, Inc.

For More Information See: http://www.plastics-car.com/FAQs/Recycling.html