Powertrain Mounting Clevis Bracket

This engine clevis bracket is the first composite mount designed for a 6 cylinder engine, and passing peak loads of 25 Kilo-newtons of force. The injection molded part replaces metallic solutions (stamping, welding and die-casting) used previously resulting in a 45% weight save. NVH was also improved (reduction in cabin noise) due to the damping characteristics of the polyamide compared to aluminum. Corrosion resistance is improved and the part can be recycled at end of life. Seven clevis brackets were developed for different powertrain combinations and there are no warranty claims after 1.5 years of production

OEM/Vehicle General Motors 2017 Cadillac XT5 System Supplier Hutchinson

Material Supplier BASF Corporation Resin Ultramid A3WG10 CR BK00564 PA66+50%GF

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

Door Edge Protector

This industry first door guard system protects all doors from dings and scratches - and neighboring vehicles as well. The door guard is not visible until it articulates out upon opening of the door. Parts are injection molded and no metal fasteners are needed. This is a marketing feature add on of $100/vehicle offering an estimated $500K warranty savings per year.

OEM/Vehicle Ford Motor Company 2017 Ford Fiesta System Supplier Witte Automotive Material Processor    Witte Automotive

Material Supplier Washington Penn Resin H2TF-2B PP Tooling/Equipment Supplier Witte Automotive

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

Plastic Clip for Door Integrated Window Regulators

These industry first plastic clip attachments secure the IWR mechanism to the side doors (46 clips/vehicle). They replace metal fasteners and weld nuts for a weight savings of .44 lbs per vehicle. Estimated cost savings include $350K for reduced cycle times, $210K for scrap cost elimination and $250K per plant as no tools are required. Customer benefits include improved fuel efficiency, better crash performance (energy absorption) due to the flexibility of the carrier, improved NVH and acoustic performance of the doors.

OEM/Vehicle Ford Motor Company 2017 Ford Fiesta System Supplier Brose Material Processor    Brose

Material Supplier Omni Plastics Resin Omni Lon 6/6 PA66 Tooling/Equipment Supplier A. J. Raymond

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

Engine Bracket

Utilization of a 50% glass reinforced polyamide for engine brackets enabled improved NVH in the powertrain. An innovative injection molding tooling concept with 1 +1 tooling (including hot runner and pressure transducer for continuous process control for both the left and right side bracket) was developed for production. This is the first time two cavity tooling with a hot runner system plus two pressure transducers for each cavity, enabling the continuous monitoring of the process, have been utilized. A cost savings of, up to 20% compared to metal brackets and up to 15% compared to aluminum brackets, was achieved.

OEM/Vehicle Daimler AG 2017 E-Klasse Coupé System Supplier ElringKlinger Material Processor    ElringKlinger

Material Supplier Dupont Automotive Resin Zytel 70G50 HSLA PA 66 GF50 Tooling/Equipment Supplier HummelFormen

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

Flexible PPS Fasteners for High Heat Applications

This first time application allows plastic (PPS – Polyphenyline Sulfide) to replace metal and/or shielded nylon in high heat fastener applications. A 50% weight savings was achieved via elimination of metal fasteners and the elimination of shielding with a cost savings of over $20,000. Flexibility was maintained after high-heat exposure without shielding and assembly and ergonomics were improved. This technology is transferrable to many high-heat harness applications underhood or near the exhaust.

OEM/Vehicle Ford Motor Company 2018 Ford F150 System Supplier Lear Corporation Material Processor    HellermannTyton

Material Supplier Celanese Resin Fortron FX72T6 PPS

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

High Performance Carbon Composite Strut

A standard steel strut was replaced by a pultruded composite strut with bonded metal joining elements, improving NVH, eliminating corrosion concerns, and optimizing the specific stiffness/weight ratio while reducing mass 45%. The 50K tow unidirectional carbon fiber-reinforced epoxy also features an insulating fiberglass layer to prevent stone chipping and provide galvanic protection. The cost-effective application produces no scrap and is being used on medium-volume vehicles (up to 30,000/year).

OEM/Vehicle Daimler AG 2016 Mercedes-AMG C-Class Coupé System Supplier Secar Technologie GmbH Material Processor    Secar Technologie GmbH

Material Supplier Toho Tenax Resin RTM

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Electrical-System/Circuit-Boards-and-Wiring-Harnesses.html?css=print

Electronic Power-Steering Pulley

Project goals were to find ways to reduce cost without reducing performance of the electric power-steering gear-assist mechanism by replacing a powdered metal pulley with an injection molded plastic one. A high-flow grade of 60% GR-PA 4/6 that produces a resin-rich surface for improved belt wear was selected. It offers significant cost savings and reduces mass over 50% vs. the metal pulley. Its assembly method eliminates 3 bolts, which are replaced by a retaining ring. The molded torque tooth provides secure orientation and excellent load-carrying capabilities.

OEM/Vehicle General Motors Co. 2017 GMC Acadia System Supplier Nexteer Automotive Material Processor    PRISM Plastics

Material Supplier DSM Engineering Plastics Resin Stanyl TW241F12 PA46

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

Blow-Molded Grille Reinforcement

This blow molded grille reinforcement adds stiffness to the chromed ABS grille assembly to meet OEM load/deflection and sightline/aesthetic requirements. The 20% GR-PP part assembles to the B side of the grille assembly within manufacturing tolerances yet meets thermal expansion/contraction characteristics of the grille without affecting the design profile by remaining hidden. Deflection under load for the unreinforced grille was reduced by 66%, while cost and weight were each reduced by 25% vs. a stamped steel reinforcement solution. A single parison is dropped, and excess material is punched out and then reprocessed to form subsequent parts.

OEM/Vehicle Nissan Motor Co. Ltd. 2016 Nissan Titan System Supplier SRG Global 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/Todays-Automobiles/Automotive-Chassis-Design-NVH-Performance/Support.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

Dual Snap Hardware Mechanism

This is the first rear-door, window-lift carrier-plate mechanism that is all-plastic and features a double (dual) snap. It delivers design flexibility, labor cost savings, and greater design efficiency with multiple glass constructions, meeting project goals to reduce processing and assembly time, maintain rotational stability, and reduce design complexity. An injection molded, 2-shot, TPC-ET overmolded POM design integrates both a down-stop bumper and a glass bumper, eliminating a component and assembly steps. The innovative design also includes an additional snap-feature attachment to support glass tracking during up/down operations.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Hi-Lex Corp. Material Processor    Hi-Lex Corp.

Material Supplier Celanese Corp. Resin Celcon POM / Riteflex M25 TPE Tooling/Equipment Supplier MPP

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

Latching Refueling Valve

This challenging new design demanded a unique material with consistent properties after prolonged exposure to fuels, superior wear characteristics, a stable coefficient of friction over a wide temperature range, superior fuel swell and exposure resistance, and superior molding capabilities to properly fill tight-tolerance micro-features. An injection molded 30% GR-PPA with PTFE micro-powder (to enhance wear characteristics) met all requirements. The application saved over $10 USD/vehicle and reduced energy consumption vs. the previous valve. The novel technology has led to 1 issued and 7 pending patents.

OEM/Vehicle Ford Motor Co. 2017 Ford Fusion & Lincoln MKZ Hybrid Electric System Supplier Continental Automotive Material Processor    Advanced Molding Tech - USA

Material Supplier DuPont Automotive Resin Zytel HTNWRF51G30 PPA 30% glass Tooling/Equipment Supplier GBMC Luxshare

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains/Transmissions.html?css=print

Rear Differential Cross-Member

This is said to be the first application where a PA/glass composite has been used as a cross-member to support the rear differential and complete the rear cradle of a vehicle. By replacing traditional parts in steel or aluminum, the injection molded glass-reinforced PA 6/6 design offered parts integration opportunities, is cost neutral, reduces noise transmission from the driveshaft, and reduces mass 25 %, helping improve fuel economy and reduce tailpipe emissions. The grade used has been optimized for dynamic loads and is controlled with tighter production specs.

OEM/Vehicle Daimler AG 2016 Mercedes S-Class System Supplier ContiTech North America, Inc. Material Processor ContiTech North America, Inc.

Material Supplier BASF Corp. Resin Ultramid A3WG10CR PA66 GF 50

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains/Drive-Shaft.html?css=print

Strut Mount

This is the first use of a glass-reinforced PA material for strut-mount housings on all 4 corners of a vehicle and the first application of polyamide housings on the front and rear suspension systems. The injection molded parts integrate common components for both front and rear mounts, and employ a special thread assembly method with a locking feature.  They reduce mass 30% vs. typical steel and aluminum parts and reduce noise transmission through the suspension system. Thanks to modular assembly, the design also offers greater tuning flexibility.

OEM/Vehicle General Motors Co. 2016 Cadillac CT6 System Supplier ContiTech North America, Inc. Material Processor    ContiTech North America, Inc.

Material Supplier BASF Corp. Resin Ultramid A3WG10CR PA66 GF 50

For More Information See: http://www.plastics-car.com/Tomorrows-Automobiles/Current-Projects/End-of-Life-Vehicle-Recycling.html?css=print

Air Induction System Mounting Structure

This air-induction system mounting structure replaced a steel part that was very complex and challenging to manufacture with an injection molded PPS/PA part. The plastic mounting system reduced mass 68%, eliminated an anti-corrosion coating, reduced production costs 64% and brought tooling savings of 50% vs. the previous steel part. Additionally, the polymer part met all application requirements for thermal stability, chemical resistance, dimensional stability, fatigue resistance, and stiffness.

OEM/Vehicle General Motors Co. 2016 Chevrolet Malibu System Supplier Toledo Molding and Die, Inc. Material Processor    Toledo Molding and Die, Inc.

Material Supplier Solvay Specialty Polymers Resin Ryton XK2340 PPS/PA Tooling/Equipment Supplier Toledo Molding and Die, Inc.

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