D Optic LED Headlamp

This innovative headlamp system features scalable modular design flexibility. The customer can add elements to achieve styling and/or performance objectives. The lenses are single shot thick molded elements, with extremely tight tolerance and high optical clarity requirements. They simplify conventional optical systems in which multiple components (reflector, shield and lens) must be positioned very precisely, with a system of pairing a precisely molded lens with a single 1 x 1 LED light source. A high temperature grade acrylic material enables the modular lenses to be placed very close to the light source, within 300 - 500 micros, to maximize the amount of light captured form the LED. The Traverse headlamp has three vertically large integrated lenses alongside six individual compact lenses.

OEM/Vehicle General Motors 2018 Chevrolet Traverse System Supplier Magna Autosystems

Material Supplier Arkema Resin Plexiglas HT-121 PMMA

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

Headlamp Light Curtain

The lamp appears crystal clear when unlit but has a glowing appearance when lit. The light scattering properties of the new material convert the light guide to a fully illuminated panel, that can be used with any color LED, opening a new degree of freedom for designers. Previously, clear PMMA without this light

scattering additive was used, and structures on the surface of the light pipe, along with multiple LEDs behind the part, had to be used. These traditional light guides and light pipes resulted in bright spots and a milky (grained)unlit appearance. The new headlamps give the consumer premium headlamp styling due to a homogeneously lit light function. Safety is enhanced as there is better visibility due to a larger illuminated surface easier to detect with the human eye. A 3D effect can also be achieved.

OEM/Vehicle General Motors 2016 Cadillac CT6 System Supplier Hella KGaA Hueck & Co

Material Supplier Evonik Cyro LLC Resin Acrylite LD96 PMMA

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

Bolster Active Grille Shutter

This integration of an Active Grille Shutter and bolster function into the front end module includes sheet metal bolt on reinforcements in the structure. Injection molding the plastic metal hybrid replaces separate molding of the two systems and a part count reduction of 20 separate parts. This saved 1.76 lbs of weight and enabled an approximate $8 cost savings. This process also improved sealing efficiency to improve heat exchanger performance. it is scalable to other OEMs or vehicle sizes.

OEM/Vehicle Ford Motor Company 2018 Ford Fiesta System Supplier Montaplast Material Processor    Montaplast

Material Supplier Lanxess Resin Durethan PA6 35GF Tooling/Equipment Supplier Farmington

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

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

Structural AGS w/Integrated Loose Layer Construction

This, possibly the largest 2-shot AGS in production today, was designed with an integrated locating and attaching system for consistent fit between the grille and headlamps eliminating the need for FEM assembly, dunnage and shipping. Savings are estimated at $5 per part system, additional $16 inside cost in addition to $45 markup and shipping, $1 in labor by eliminating 4 fasteners, and inplant tooling avoidance of $2 Million for a new cell and assembly tooling. A 1 lb weight savings was achieved, plus an additional 3 lb avoidance over a metal/plastic hybrid assembly.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition System Supplier Magna Plastcoat Material Processor    Magna Plastcoat

Material Supplier Celanese Resin Celstran 40-20 PP/GF Tooling/Equipment Supplier Integrity Tool

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

3D Radiator Grille

A new appearance is achieved for this front grille by using "varied contouring" (variable wall thicknesses) on the B side of this injection molded, tinted PC part, which subsequently is UV coated on the A side and receives a 3-coat paint system on the B side. The end result is a unique 3D look on a 2D surface.

OEM/Vehicle General Motors Co. 2017 Chevrolet Bolt System Supplier Sam Shin Chemical Co. Material Processor    Sam Shin Chemical Co.

Material Supplier LG Chem Ltd. Resin LUPOY 1000MU PC Tooling/Equipment Supplier A-Tech Solution Co., Ltd

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

Tailgate Gap Hider Assembly

This tailgate gap hider provides a structural "bridge" over the gap between the end of the pickup bed and the open tailgate, reducing debris intrusion and withstanding heavy loads without breakage or deformation during loading and unloading.  The spring-loaded unit offers 2 installation options and deploys and stows automatically during tailgate operation. A blow molded 20% glass-reinforced PP copolymer reduces mass 20% vs. structural steel solutions and offers better performance than non-structural aftermarket offerings. Special coarse texturing helps match the gap hider to spray-on bed liners while improving surface scratch resistance.

OEM/Vehicle Nissan Motor Co. Ltd. 2016 Nissan Titan System Supplier Metelix Products, Inc. Material Processor    Metelix Products, Inc.

Material Supplier Washington Penn Plastics Co, Inc. Resin PPC1GF2UV-RXF 20% GF PP Tooling/Equipment Supplier Metelix Products, Inc.

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

Low Aerodynamic Drag Bumper System

This front bumper with computer-controlled active air splitter keeps the splitter closed during straight acceleration to direct air under the body and toward the large rear diffuser/extractor, which uses the Venturi effect to convert high-pressure airflow to low pressure. During braking or cornering, the front splitter opens at the correct angle to provide a downforce of 220 lb/100 kg for improved handling. The combined system helps the vehicle achieve a best-in-class, low aerodynamic drag coefficient of 0.32 while supporting signature styling with impact and scratch resistance at lower mass and cost than the previous material.

OEM/Vehicle FCA US LLC 2017 Alfa Romeo Giulia 952 System Supplier FCA Group Material Processor FCA Group

Material Supplier SABIC Resin SABIC® 8611P PP GELOY HRA170 Tooling/Equipment Supplier Sanvito & Somaschini S.p.A.

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

MIC High Gloss Body Color TPO Fascia

Painted fascias are prone to chip and peel, which leads to warranty costs and customer unhappiness. Additionally, painting adds significant cost with negative environmental impact. Instead, a high-gloss, weather- and mar-resistant, MIC TPO material matched to vehicle body panel color. Rigorous testing was conducted to assure the material was resistant to stone pecking and road chemicals and would not change shape when exposed to high heat. Additionally, a lens-grade mold with SP1 diamond polish and gating designed to minimize knitlines was used. The resulting part is 10% lighter, offers $800,000 USD annualized savings, and harmonizes with exterior painted components.

OEM/Vehicle Ford Motor Co. 2017 Ford Transit Connect System Supplier Magna Exteriors, Inc Material Processor Magna Exteriors, Inc. - Nascote

Material Supplier Advance Composites, Inc. Resin ADX700 TPO Tooling/Equipment Supplier Tycos Tool & Die

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

Lightweight Glass

Three of 5 glass positions on this vehicle feature chemically tempered glazing that's part of a thin, hybrid laminate solution with an interlayer of solar-control PVB film that reduces glazing weight approximately 37% while lowering heat transmittance to keep interiors cooler. Versus conventional 0.20 in./4.96 mm thick laminates featuring 2 layers of soda-lime glass (SLG) with a PVB interlayer, the new construction features standard-thickness layers of SLG and PVB plus a very-thin (0.03 in./0.7 mm) layer of chemically tempered glass for a total thickness of 0.14 in./3.56 mm. The resulting laminate is thinner, lighter, tougher, and offers optical advantages.

OEM/Vehicle Ford Motor Co. 2017 Ford GT40 System Supplier Pittsburgh Glass Works LLC Material Processor Pittsburgh Glass Works LLC

Material Supplier Sekisui Chemical Co., Ltd. Resin PVB Tooling/Equipment Supplier Pittsburgh Glass Works LLC

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

Structural Front End Module with Active Grille Shutter

This all-composite design without metallic reinforcement is the first AGS -capable, injection-molded PP-LFT FEM bolster used on a heavy-duty pickup platform. Replacing steel and plastic/metal hybrids at a 3 lb/1.4 kg and $3 USD savings/vehicle, the design offers parts consolidation with locating features that aid fit & finish, improves airflow, while meeting structural requirements for part deflections of <1mm on this 8,500 lb/3,856 kg class vehicle.

OEM/Vehicle Ford Motor Co. 2016 Ford Super Duty System Supplier Shape Corp. Material Processor  Shape Corp.

Material Supplier Celanese Corp. Resin Celstran PPGF

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

Front Door Polycarbonate Windows

This application is the first, fully homologated, lightweight, race-like front door with sliding window in polycarbonate glazing and protective plasma surface treatment that met all performance and homologation requirements. The door's polycarbonate glazing also features a sliding rail and small moving plastic glazing with water management. Although the solution is not feasible in conventional glass, the current design is approximately 40% lighter than glass would have been. The application is a good example of using plastics to excite and better appeal to customer while enabling regulatory compliance, homologation, and mass reduction for better performance.

OEM/Vehicle FCA Italy S.p.A. 2015 Abarth 695 Biposto System Supplier ISOCLIMA Material Processor Exactec LLC

Material Supplier SABIC Resin LEXAN PC with EXATEC coating 9030HO-GN9018T

For More Information See: http://www.plastics-car.com/Automotive-Center/Member-Companies?css=print

Charge-Port Bezel

Thanks to use of elastic averaging, this injection-molded charge-port bezel is located very precisely with no gaps or movement normally associated with typical cantilevered snap-fit components. The application also used molded-in-color POM material, which provided the appearance of chrome without the cost or environmental concerns. The design also helped reduce labor to install and ensure the part was centered in the charge-port opening.

OEM/Vehicle General Motors Co. 2016 Chevrolet Volt System Supplier ITW Deltar Material Processor ITW Deltar

Material Supplier Celanese Resin MetaLX Hostaform POM Tooling/Equipment Supplier ITW Deltar

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