Rear Seat Entertainment System

This Rear Seat Entertainment System was repositioned from the back of the front seat headrest to the upper seat back/lower portion of the head rest area for improved viewing comfort and ergonomics. No change in the existing seat structure was required with this common design for both the driver and passenger seat. The DVD system was removed to enable a larger screen and this resulted in a 30% cost reduction.

OEM/Vehicle Ford Motor Company 2018 Lincoln Navigator System Supplier Magna Material Processor    Great Lakes Trim

Material Supplier Advanced Composites Resin ADX 5028 PP Tooling/Equipment Supplier Great Lakes Trim

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

Storage Box Interlocking Down Stop

An interlock is integrated into the traditional GB down stop design to make the TPO down stop super strong and still achieve very low disengagement effort for service and assembling. For the traditional design, low disengagement effort for service or assembling and robust down stop for customer abuse conflict with each other. Making one better will worsen the other. The interlocking down stop design decouples the two and allows for engineers to lower the disengagement effort and strengthen the down stop as needed. This results in a cost savings of $.90 per vehicle ($.50 piece price savings and $.40 labor savings) compared with removable down stops.

OEM/Vehicle Ford Motor Company 2018 Lincoln Navigator System Supplier DMS Material Processor    DMS

Material Supplier Advanced Composites Resin ATX 832N PP Tooling/Equipment Supplier Lamko Tool & Mould Inc.

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

Cargo Protector

This cargo protector eliminates a major design flaw on large SUVs by blocking the dynamic progress of rolling containers such as grocery items or objects such as small sports items while preventing them from falling out of the vehicle when the liftgate is opened. It also prevents items from "perching" on the scuff when the liftgate is closed, and avoiding item roll-out when the liftgate is opened by limiting the upper flat surface of the scuff and how it interfaces with the liftgate trim. The scuff's beveled surface allows much easier removal of cargo items than a square-edged surface which is fairly common on small and mid-sized SUVs and CUVs.

OEM/Vehicle Ford Motor Company 2018 Ford Explorer, Lincoln Navigator System Supplier Beach Mold Material Processor    Beach Mold

Material Supplier ExxonMobil Resin 7885 PP Tooling/Equipment Supplier ToolPlas Systems, Inc.

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

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

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

Thin Wall Floor Console Carrier

This floor console carrier is unique with its 2.0 mm nominal thin wall thickness (with ability to implement lightening holes) and 40% Long Glass Fiber PP construction with first surface quality appearance. A 30% mass savings resulting in a 2.2 lb/.99 kg weight savings, and a 15% cost savings was achieved. Lateral stiffness targets were exceeded eliminating the need for metal brackets ($1.50). It is also the first time injection molding was used to process this type of a component.

OEM/Vehicle General Motors 2017 Buick Enclave, Chevy Traverse System Supplier NYX Material Processor    NYX

Material Supplier Celanese Resin Celstran 40-0453 PP GF Tooling/Equipment Supplier Integrity

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

MIC Discrete PAB Cover

Passenger airbag covers are often painted, which is costly and can lead to warranty issues. Traditionally, molded-in-color was not feasible because the TPO material used did not meet Class A surface requirements. A new MIC cover design with a recessed surface and new styling line improves appearance of the tear line eliminated painting and saved 35% of the total cost for these parts. Integrating a new and complex cooling system for both the A and B surfaces helped reduce sinks and gloss variance, while injecting through a rib instead of directly onto the B surface improved aesthetics further. 

OEM/Vehicle Ford Motor Co. 2016 Ford Ka System Supplier ZF TRW Material Processor Demo do Brasil

Material Supplier APIGO Resin APIGO DP 2476 TPO Tooling/Equipment Supplier Demo do Brasil

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

Modular Dual-Layer Seat System

Thanks to integrated composite designs, this "perfect position seat" suspension system delivers tuned suspension to optimize occupant comfort by cradling the upper back and providing side-torso support, which flexes to accommodate various occupant sizes. Special attachment features facilitate assembly and service time. The design also creates a robust dynamic crash-energy management system for rear-impact protection. Molded-in-color is used for A surfaces and craftsmanship. The system, for which 83 patents have been filed, reduces total seat weight by 8% and cost by 15% despite adding more features.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Leggett & Platt Inc. / Magna International Material Processor    Summit Plastic Molding / Century Plastics

Material Supplier BASF Corp. / Advanced Composites, Inc. / DuPont Automotiv Resin ULltramid B3ZG7 OSI / Ultramid B3EG3 / ADX 5017 / Delrin 100 Acetal Tooling/Equipment Supplier Summit Plastic Molding / Mega Mold

For More Information See: http://www.plastics-car.com/FAQs/Plastics-Life-Cycle-Analysis.html

2nd-Row Collapsable Under-Seat Bin

This innovative second-row under-seat storage bin is designed to expand, collapse, and lock from either side of the pickup. When stowed, the bin maintains a low profile (with no mechanisms exposed) to allow use of the load floor. When expanded, it provides a large amount of usable storage. The tough injection molded TPO resin meets all fit/finish and toughness requirements to -30oC, while enabling use of a 4-pin hinge design to be molded in a large plastic assembly.

OEM/Vehicle Ford Motor Co. 2017 Ford Super Duty System Supplier Yanfeng USA Automotive Trim Systems Co., Inc Material Processor   Yanfeng USA Automotive Trim Systems Co., Inc

Material Supplier Advance Composites, Inc. Resin TPO Tooling/Equipment Supplier Circle 5 Tool & Mold

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

Living-Hinge Cup Holder Adjustment Features

Cup holders are a focal point for customer critiques of vehicle interiors. Further, they must accommodate a wide range of container sizes without tipping during normal driving conditions. Incorporation of a living hinge (achieved via molded-in "fingers" and a flexible silicone-rubber band) in this cup holder design made it adjustable to accommodate many containers while reducing 10 parts to 3 with no secondary heat-stake operations. Furthermore, the design reduces part costs ≈ $1.50 USD/assembly, lowers tooling expenditure ≈ $100,000 USD, yet delivers equivalent appearance and performance.

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

Material Supplier Advance Composites, Inc. Resin 20%TF PP + EPDM

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

Thin-Wall IP Substrate

Reportedly, this is the thinnest full-size, deep-draw injection molded IP in North America at 1.9 mm/0.07 in. It was achieved by injection molding a 30% glass-reinforced LFT-PP. Versus the 2.4 mm/0.09 in. microcellular molded benchmark, this design was 14% lighter, saved over $1 USD in materials as well as the microcellular-foaming investment, and helped optimize packaging. Mold filling analysis with fiber orientation was used for accurate warpage predictions and to develop tooling countermeasures to facilitate part molding.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Faurecia Interior Systems Detroit Manufacturing Systems Ltd., LLC Material Processor   Faurecia Interior Systems

Material Supplier SABIC Resin STAMAX 30YK270E 30% GFPP Tooling/Equipment Supplier Lamko Tool & Mold Inc.

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

Ultrathin Seat Back

To solve the challenges of conventional seat construction, which limits console storage and rear-seat leg room, this product eliminates molded urethane foam from the seat back and replaces it with an all-plastic shell featuring a larger concave region that enables optimum occupant comfort. An innovative suspension system also is used that consists of a forward plastic seat back panel attached to the frame via spring joints. The technology can increase front console width by ≈ 0.8 in./20 mm and reduce seatback thickness by ≈ 2.1 in./52 mm or reduce overall vehicle cost $35-$40 USD and mass 3-4 kg.

OEM/Vehicle General Motors Co. 2017 Chevrolet Bolt EV System Supplier General Motors Co. Material Processor    USF

Material Supplier Advanced Composites, Inc. Resin GMW15548P-PP/PE-M15-Type 6A,    GMW15548P-PP/PE-M20 Type 4  GMW16582P-PA6-GF15 Tooling/Equipment Supplier ToolPlas Systems Inc.

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