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

Window Frame Surround

To meet window-frame surround requirements for high stiffness, low gloss, good surface quality and haptics, colorability with good processability, high scratch and UV resistance, and dimensional stability, a new 25% GR-TPO compound was developed to replace 15% GR-PA 6. The new grade offers higher stiffness, which facilitates thin-wall part design. It does not require drying prior to processing and its properties are not affected by ambient changes in humidity. The result is an 8% weight savings and ≈18% piece-cost savings.

OEM/Vehicle Daimler AG 2015 Mercedes-Benz GLC, GLC Coupe & E-Class System Supplier Dr. Schneider Automotive Group Material Processor    Dr. Schneider Automotive Group

Material Supplier LyondellBasell Resin Softell TKG 317N PP Tooling/Equipment Supplier Krumpholx

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Body-Exterior/Bumpers-Fascia-Systems.html?css=print

EV Home Charging Station

To meet demanding performance requirements for EV home charging unit base plates, a special flame-retardant PC/siloxane compound was developed. The material contains no halogenated additives, offers excellent low-temperature toughness and weatherability, plus improved chemical resistance. Additionally, the PC/Si material provides superior moldability for parts with deep cavities and low draft angles, and crack resistance at pinch points, which makes it easier to attach the plate with screws to home or garage.

OEM/Vehicle Daimler AG 2016 Daimler EV Fleet System Supplier ABL Sursum Material Processor    ABL Sursum

Material Supplier Trinseo LLC Resin EMERGE PC/Si XZ92705.00 PC

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

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

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

High Gloss Entertainment System Bezel

This injection-molded frame for a DVD video bezel had to provide high dimensional stability, reduce warpage, lower weight and cost, and achieve a high-gloss Class A surface finish. Replacing an earlier 2-part design featuring multi-layer painting, a single-piece part met all performance requirements thanks to the combination of two process technologies:  microcellular foaming and tool heating/cooling.  This led to a 40% weight savings and a 20% cost savings as well as additional 10% product cost savings while improving global quality perceptions due to excellent appearance and lower NVH.

OEM/Vehicle Daimler AG 2013 Mercedes-Benz S-Class luxury sedan System Supplier Johnson Controls Inc. Material Processor Groupe Plastivaloire (PVL) / Trexel, Inc.

Material Supplier Bayer MaterialScience Resin T65 XF ABS/PC Tooling/Equipment Supplier Groupe Plastivaloire (PVL) / Trexel, Inc.

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

Roof Ditch Molding

An innovative film transfer paint system on this roof-ditch molding provides a Class A surface with the same high performance as wet body paint systems and the processing of plastic film technology. Combining a metal carrier, a thermoplastic adhesive, and the transfer paint system (made up of a base and clear coat), the system provides high scratch resistance and sufficient elongation for stretch bending.

OEM/Vehicle Daimler AG 2014 Mercedes-Benz C-Class luxury sedan System Supplier Kunststoff-Technik Scherer & Trier GmbH & Co. KG Material Processor Kunststoff-Technik Scherer & Trier GmbH & Co. KG

Material Supplier Karl Wörwag Lack- und Farbenfabrik GmbH & Co. KG Resin F2310-120 paint transfer system Tooling/Equipment Supplier Kunststoff-Technik Scherer & Trier GmbH & Co. KG

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

High-Heat Turbo EGR Sleeve

This heat shield is integrated into the air-intake manifold inlet for high air-temperature applications like diesels.  In this area of the manifold, hot exhaust gas (EGR) is mixed with ambient-temp (fresh) air without failure of adjacent components.  The plastic heat shield offers several improvements vs. previous systems including greater design flexibility (molded-in vs. machined geometry); improved air/EGR mixing (thanks to molded features, which increase turbulence); 50% weight savings; enhanced component durability; and inherent corrosion resistance. A special heat-stabilized grade of 35% GR PA 6/6 is injection molded for the sleeve, replacing roll-formed aluminum and readily withstanding the continuous-service temperature of 220C and peak temperature of 240C. The application was cost neutral but reduced mass by 50%.

OEM/Vehicle Daimler/Mercedes 2013 I-4 turbo diesel engines System Supplier Montaplast GmbH Material Processor Montaplast GmbH

Material Supplier BASF Resin Ultramid D3G7 PA66

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

Oil Pan Module

This is the first modular plastic oil pan module adopted for passenger cars. It integrates an uppers hell of diecast aluminum and a multifunctional lower shell injection molded from glass-reinforced nylon 6/6.  An integrated windage tray (oil deflector) reduces oil vapor around the crankshaft (improving horsepower 5%), lowers air entrapment in the oil, and decreases friction for longer bearing life. The component is 2.4 lb/1.1 kg lighter and 20-25% less costly than an all-aluminum design and use of integrated oil baffles improves flow and reduces sloshing of oil.

OEM/Vehicle 2008MY Daimler AG Mercedes® C-Class 4-Cylinder Diesel Sedan  System Supplier G. Bruss GmbH  Material Processor G. Bruss GmbH

Material Supplier DuPont Automotive  Resin Zytel®  70G35  PA 6/6

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

Eye-Level Panoramic Roof System

Produced via injection-compression molding, this is the largest eye-level panoramic roof system in the world and makes use of polycarbonate.  The system increases the daylight-opening space of the vehicle while reducing mass a nominal 40% vs. glass.  The roof is tough, resistant to cracking during side impacts, and has low HIC values for added safety.

OEM/Vehicle 2008MY Daimler AG Smart for Two® Minicar System Supplier Webasto Material Processor Webasto

Material Supplier Bayer MaterialScience AG Resin Makrolon® AG2677  PC Tooling/Equipment Supplier InGlass

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

Plastic Intensive Fluid Filter Module

This fluid module filters engine oil and cools it via cooling liquid. The cooling unit is fully integrated into a new plastic housing that provides 38% weight and 16% cost reductions and reduces pressure losses for higher engine efficiency. The 35%-glass-reinforced nylon 6/6 shell covering the cooling unit serves to stiffen the filter housing against oscillation. A plastic hose replaces rubber for further cost savings.

OEM/Vehicle 2010MY Daimler AG-Mercedes Car Group:  Mercedes® C-Class Compact Executive Sedan System Supplier Mahle Filtersysteme GmbH Material Processor Mahle Filtersysteme GmbH

Material Supplier Lanxess Resin Durethan® AKV 35%-GR PA 6/6 Tooling/Equipment Supplier Mahle Filtersysteme GmbH

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

Turbo Charge

A new injection-molded PA 4/6 resin offering good weldability and excellent long-term heat aging and mechanical-property retention to 220C proved ideal for meeting relevant requirements in this turbo charge air-duct resonator.  Replacing metal, the application reduced mass by 50% and cost by 20%.

OEM/Vehicle Daimler AG 2010 Daimler Sprinter System Supplier Woco Group Material Processor Woco Group

Material Supplier DSM Engineering Plastics Resin Stanyl Diablo OCD2100 PA 46

For More Information See: http://www.plastics-car.com/Tomorrows-Automobiles/Automobile-Designs-of-the-Future