Instrument Panel Carrier

Long glass fiber PP injection molding via structural chemical foaming with core-back process enabled the production of this part with very low VOC emissions, meeting VDA 278 specification. Extensive CAE work predicting warpage of the foamed part provided valuable insights, allowing for the modification of tooling in advance. Use of foaming means less material is required resulting in a 15% weight savings, fewer emissions and less cost.

OEM/Vehicle BMW 2017 Countryman System Supplier International Automotive Components (IAC) Material Processor    International Automotive Components (IAC)

Material Supplier SABIC Resin Stamax PP LGF Tooling/Equipment Supplier Siebenwurst

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

Carbon Core Structural Components

Carbon fiber-reinforced fast-cure epoxy and high-pressure RTM and liquid compression molding (LCM) are used to produce 27 CFRP parts for the vehicle's mixed-material BIW structure to support production volumes of 80,000+ vehicles/year. The HP-RTM roof arc follows the shapes of the car body and offers an outstanding weight/performance ratio. The LCM tunnel reinforcement improves the vehicle's torsional stiffness and is produced in <1 min. These "carbon core" parts replace metal, improve stiffness, ride/handling, and safety while reducing vehicle mass 40 kg for better fuel efficiency and tailpipe emissions.

OEM/Vehicle BMW Group 2015 BMW 7 Series Sedan System Supplier BMW AG Material Processor    BMW AG

Material Supplier Hexion Inc. Resin EPIKOTE/EPIKURE Epoxy

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

Headlamp Shutter / Integrated Back-Lighting Ring

Replacing high-temperature PC with an LCP in this injection-molded headlamp application, the part meets all thermal requirements without plating, coating, or special treatment in a thinwall design that provides excellent creep and long-term property retention. Colors are heat-stable and the polymer is inherently flame retardant. A very-thin cold runner is used to mold the material in an extremely short cycle and with 30% less sprue waste. The change was cost neutral yet yielded better properties and higher part quality with less scrap.

OEM/Vehicle BMW AG 2014 4 Series executive coupé System Supplier Automotive Lighting Material Processor Formplast CZ

Material Supplier Celanese Resin Vectra E531i – D3 LCP Tooling/Equipment Supplier Formplast CZ

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

Rear Seat Cushion Riser

This application combines stamped steel and expanded PP bead foam to provide a lightweight, structural replacement for conventional stamped steel floor pans, while allowing common architectures and assembly steps to be used between 5- and 7-passenger vehicles. Insert molding of the steel / EPP foam component eliminated the need for secondary assembly, and saved 3.9 kg of mass and  $2.8-million in tooling investment.

OEM/Vehicle 2007 BMW ® X5 ® cross-over SUV by BMW AG System Supplier JSP International Material Processor JSP International

Material Supplier JSP International Resin Arpro ® Polypropylene Tooling/Equipment Supplier JSP Mold

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

Twin-Sheet Blow-Molded Fuel System

Twin-sheet blow molding offers the advantages of an extrusion blow-molded fuel system with the design flexibility of a half-shell process. Sheets extrude between a central core and the mold. Core actions attach the components during initial sheet forming.  The empty core is withdrawn and the mold is closed to join the formed sheets. Fuel tanks formed via this process meet the strictest PZEV emissions requirements, while also providing higher tank capacity, lower emissions, weight and cost reductions, and elimination of post-mold operations.   

OEM/Vehicle 2009MY BMW AG BMW® Series 7 Sedan System Supplier Inergy Automotive Systems Material Processor Inergy Automotive Systems

Material Supplier LyondellBasell, Kurrary & Mitsui Resin Lupolen® 4261  HDPE Tooling/Equipment Supplier Inergy Automotive Systems

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

Door Panel in Natural-Fiber Prepreg Composite

This lower door-panel inner was compression molded from a new, high-performance, lightweight, cost-effective, and green composite. The resin matrix is a unique acrylic polymer that is thermoplastic in its “B-stage,” allowing for production of prepreg/semi-finished rollstock or blanks, yet cross-linking at temperatures above 120C to produce a very durable thermoset. The resin’s high wetout of natural fibers and ability to form chemical as well as mechanical bonds to the reinforcement allows for very-high fiber loadings – 70% in this case – yielding lightweight parts with high stiffness in thin walls. This saves weight and cost, and reduces VOCs. And the rapidly renewable natural fiber mat reduces the vehicle’s carbon footprint without sacrificing performance.

OEM/Vehicle 2008MY BMW: BMW®  7 Series Luxury Sedan System Supplier Dräxlmaier Group Material Processor Dräxlmaier Group

Material Supplier BASF AG & J. Dittrich & Söhne GmbH Resin Acrodur® Acrylic Copolymer

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

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

High Duty Light Weight Engine Mounts

For the first time, a highly loaded transmission cross-beam with integrated hydraulic mounts was achieved in a lightweight plastic design thanks to use of injection-molded, 50%-glass-reinforced PA 6/6.  Replacing rubber/steel and rubber aluminum, the nylon design was designed to meet the rigorous requirements of this application with regard to acoustics, crash, fatigue, and high-temperature stability.  The result was a 50% weight savings, as well as in-house production integration at the systems supplier, leading to further reductions in logistics and transportation costs.

OEM/Vehicle BMW AG 2009 BMW 550i & 750i System Supplier ContiTech Vibration Control GmbH Material Processor ContiTech Vibration Control GmbH

Material Supplier BASF SE Resin Ultramid A3WG10CR PA 66 GF 50

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

Low-Gloss, Molded- in-Color Steering- Column Cover

Use of a new lower gloss, molded-in-color ABS/PC blend eliminates the need for painted ABS/PC blends and provides improved thermal performance vs. straight ABS and PP. The part also provides improved dimensional stability vs. PP.  The application saves $1-3 USD / part depending on part size due to elimination of paint and associated scrap.

OEM/Vehicle BMW AG 2011 BMW 5 Series mid-size luxury sedan System Supplier Leopold Kostal GmbH & Co. KG Material Processor Leopold Kostal GmbH & Co. KG

Material Supplier SABIC Innovative Plastics Resin Cycolac DL100LG ABS/PC

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

In-Mold Coating Slush Process

This is the first in-mold-coating (IMC) - Slush process to produce instrument-panel skins. The process allows surface properties of a slush-molded skin to be decoupled from the substrate properties. By optimizing the surface and the substrate independently, conflicting customer requirements can be met. Cost savings of 30% were realized through the use of a lower cost aromatic TPU grade.

OEM/Vehicle 2006 MY BMW E63 M-Version System Supplier Intier Automotive Eybl Interiors GmbH Material Processor Intier Automotive Eybl Interiors GmbH

Material Supplier Bayer Material Science Resin Desmopan® 3790 AP TPU Tooling/Equipment Supplier Galvanoform

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