Natural Fiber-Reinforced PP

This 20% hemp-filled PP reduces part weight up to 25% vs. higher density glass-reinforced PP and allows wall stock to be lowered to 2 mm. Thanks to the 20% bio content, this also reduces the part's CO2 emissions 20% during its use life. The material is fully recyclable, and can be processed on conventional molding machines at lower energy consumption.

OEM/Vehicle PSA Peugeot Citroën 2013 Peugeot 308 System Supplier Faurecia Interior Systems Material Processor Faurecia Interior Systems

Material Supplier Automotive Performance Materials Resin NAFILEAN PF2 PP/NF20

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

Integrated Semi-Convertible Sunroof System

This is the first all-thermoplastic, 1-piece GR SMA/ABS composite sunroof frame that is 2x1 m in size. Large sunroof frames such as this are typically formed from aluminum extrusions or steel stampings, while smaller frames have been produced in SMC or hybrid PBT/ASA and metal. The integrated system combines 7 parts into 1 while incorporating both structural and customer-visible surfaces with an integrated textile canopy plus kinematics. The injection-molded frame is mounted to the upper-body structure and combines operating functionality for a sliding sunroof.  Tooling was designed to simultaneously mold both sunroof frame plus rear-window frame via a sophisticated runner and hot-drop system that minimized part stresses, and eliminates cooling fixtures, a second tool, and a second press, and provided repeatable manufacturing. The result is a durable system that is 100% recyclable, eliminates paint (lowering VOC emissions), offers 40% lower weight than previous systems, and contributed 25% tooling savings.

OEM/Vehicle PSA Citroën 2013 DS 3 Cabrio supermini System Supplier Webasto Group Material Processor Shapers ARRK

Material Supplier Polyscope Polymers BV Resin XIRAN SG230EB SMA & ABS Tooling/Equipment Supplier Shapers ARRK

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

Rear Quarter Windows

This PC rear quarter window with 3D styling is integrated into the vehicle's aerodynamic spoiler (to facilitate vehicle stability and improve fuel economy) and D- and roof pillars (without need for styling gaps). It is the largest rear quarter window in plastic glazing to date and its unique contours would have been unfeasible in glass, although it is also 20% lighter than glass.  In addition, the 2-shot injection/compression part has low residual stresses, was double-baked with a silicone hard coat for durability and weathering performance, and features an integral molded-in-color PC/ABS surround.

OEM/Vehicle PSA Peugeot 2011MY Citroën DS5 System Supplier Freeglass GmbH Material Processor Freeglass GmbH

Material Supplier SABIC Resin Lexan GLX 143 PC

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

Self Reinforced Airbag Door System

This is the auto industry’s first airbag door system that integrates an all-PP construction, (PP-fiber-reinforced PP).  As such, it is fully recyclable and does not require typical post-mold scoring / weakening of the door flap.  The injection-molded door system is the lightest, least-expensive system solution, since additional components and post-mold operations (to enable the door flap to open / hinge) are eliminated.  Multi-zone temperature control of the mold was required, as was use of a vacuum-holding system for the fabric insert.  The program also required development of a specialized fiber-reinforced material to facilitate overmolding and subsequent adhesion. The resulting system reduced weight between 30% & 300% weight vs. competitive systems and saved approximately $5 USD/part vs. welded systems.  Additional indirect savings of approximately 5% were also accrued, and production scrap is 100% recyclable.

OEM/Vehicle PSA Citroën 2008 Citroën C5 System Supplier Visteon Corp. Material Processor Visteon Corp.

Material Supplier LyondellBasell & Propex Fabrics Resin PP

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