Grill Opening Reinforcement

This is the first Grill Opening Reinforcement with 100% Post Consumer Recycled Carpet Fiber Material. The material was a direct drop in with no tooling adjustments required. A 10% cost save was achieved using the recycled material compared to new material. The application recovered 536,667 yards (84 football fields) carpet. The GRO structurally ties the upper rails to the lower frame rails. It provides the general shape of the frontend and absorbs energy during a frontal impact. It also provides for a rigid mount for a crash sensor and facilitates attachment schemes for components such as head lights, hood latch and front fascia assembly.

OEM/Vehicle Ford Motor Company 2017 Lincoln MKC, Ford Fusion System Supplier Montaplast / Magna Material Processor    Montaplast / Magna

Material Supplier Wellman Advanced Materials Resin Ecolon GF3030 & GF1960 PA6

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

Low VOC and Odor Polyurethane Headliner

New low VOC and odor regulatory requirements in the Asia Pacific region were achieved on this polyurethane headliner, one of the largest interior trim parts. New materials - ISO and Polyol Process, general foam pouring and curing applications, and wet PU compression molding processing made this possible. Also, a special air ventilation system during foam curing and the slicing process was developed. Chemical additives were added into the wet PU processing to reduce VOC. This project initiated the commonization of raw materials for headliners across the AP region and has the potential for  optimization/globalization of a headliner bill of materials.

OEM/Vehicle Ford Motor Company 2018 Ford EcoSport, Fusion & Kuga System Supplier Grupo Antolin Material Processor    Grupo Antolin

Material Supplier BASF Corporation Resin 119M2 ISO/Poly 119M2 Tooling/Equipment Supplier Grupo Antolin

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

Post Consumer Recycled PA66 for Window Support Bracket

For this application, 100% PCR (Post Consumer Recycled) PA66 resin replaced virgin PA66 and PP resins to provide high damping properties to reduce or eliminate squeak, rattle and window vibration. As damping properties are inherent in PA 66 resin, no new product development was required. As the same injection

molding process used to process the former resins as the new recycled material could be used, no new tooling was required either. This process can be translated to other applications further reducing landfill waste.

OEM/Vehicle General Motors 2016 Chevrolet Silverado, GMC Sierra System Supplier Cooper Standard Material Processor    Cooper Standard

Material Supplier Ravago Resin Enviramid N1335HL, 30167 35% GFR, PCR, PA66

For More Information See: http://www.plastics-car.com/Automotive-Center/Fact-Sheet

Ultra Capacitor Barrier Shield

This application uses material recycled from tires and plastic caps to make TPE shields to protect the ultra capacitor from the hotter surrounding environment by deflecting heat away from it. This has prevented 5,000 tires and 25,000 lbs of plastics from landfills to date. Die cutting, thermoforming and vibration welding is used to produce this part for the first time, opposed to 2-shot injection molding, resulting in an $80,000 savings in tooling compared to tooling for steel or aluminum used previously. A 16 week same save is also achieved. Consumers benefit as the heat shields keep the battery cool preventing possible battery failure. This application can be translated to other exterior applications.

OEM/Vehicle General Motors 2018 Cadillac CTS System Supplier GDC Incorporated Material Processor    GDC Incorporated

Resin Enduraprene 2390/2195Re TPO Tooling/Equipment Supplier GDC Incorporated

For More Information See: http://www.plastics-car.com/Automotive-Center/Mission

Closed Loop Plastics & End-Of-Life Resin Use

Folding seat modules and plenum ducts are being produced with recovered 100% PCR PET resin from water bottles from CAMI Assembly Plant. The Lavergne Group Inc. has worked with GM CAMI Assembly Plant’s Global Environmental Compliance and Sustainability - Canada Region to implement the bottle collection program at the Lavergne facility. The recycled PET plastic is washed, flaked and turned into pelletized sustainable engineering resins. Bottle collection started in February 2017. This project is a demonstration of circular economy, bringing water bottles from CAMI, a landfill free, zero waste operation, processing them and returning those bottles in the form of a component to the same plant that generated the bottles.

OEM/Vehicle General Motors 2017 Chevrolet Equinox, GMC Terrain System Supplier Windsor Mold Group Material Processor    Windsor Mold Group

Material Supplier Lavergne Resin VYPET VNT 835 35% GFR, PCR, PET Tooling/Equipment Supplier Windsor Mold Group

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

Use of Soybean Oil in Slap Pad

This is the first use of soybean oil, to replace up to 40% of the 100% petroleum oil in the natural rubber part. It can be translated to any vehicle line with leaf springs including trucks, vans and SUVs. The current volume of petroleum oil being replaced in this application is approximately 522 gallons/year. This replacement of petroleum oil, with a natural resource, also offers a reduction in noise and an improvement in part durability. This will result in a reduction in warranty replacement of slap pads, estimated as a $2.5M warranty cost avoidance.

OEM/Vehicle Ford Motor Company 2018 Ford F150 System Supplier Rassini Material Processor    Rassini

For More Information See: http://www.plastics-car.com/Recycling/Life-Cycle-Assessment-Public-Policy-Development

Next Generation Sustainable Content Bio Foam

This application provides a sustainable alternative to conventional petroleum based foams - at a lower weight and cost with more design flexibility. Caster based foam provides for a lower molded density and ability to be foamed in as little as 4 mm cross sections, and superior bond strength to mating materials. Foam in place tooling, where a cast PVC, TPE, or TPU skin is placed in the mold with a hard plastic retainer and the foam is injected between these two components, is used for processing. A weight savings of 20 - 40% (depending on foam thickness) and a cost savings of $2 per average foamed in place instrument panel is achieved.

OEM/Vehicle Ford Motor Company 2018 Ford Fusion System Supplier International Automotive Components (IAC) Material Processor    International Automotive Components (IAC)

Material Supplier BASF Corporation Resin Elastoflex 3496/102 Resin, 113/4 Iso PU

For More Information See: http://www.plastics-car.com/Recycling/Life-Cycle-Use-Phase-of-a-Cars-Life

Seat Armrests in Recycled Nylon

Part performance was improved and manufacturing costs were reduced using 100% recycled nylon 66 (33% glass-filled) with strength properties exceeding the original 40% long-glass filled polypropylene material's performance. The recycled nylon was formulated to utilize identical shrink values as the polypropylene (original substrate material) avoiding tooling cost and timing impacts. A cost avoidance of $0.35 per armrest was realized by utilizing recycled glass filled nylon instead of virgin glass filled nylon. A significant safety benefit is also achieved as the recycled material provides the armrest with a 60% increase in breaking strength above FCA specifications.

OEM/Vehicle FCA US LLC 2016 Chrysler Pacifica System Supplier Williamston Products Inc. Material Processor    AGS Technology Inc.

Material Supplier AGS Technology Inc. Resin Injectoblend FPA66235-2RU PA66 33FG Recycled Tooling/Equipment Supplier Aalbers Tool and Mold

For More Information See: http://www.plastics-car.com/Recycling/Recycling-of-End-of-Life-Vehicles_1

Biomass-based Polyester Blend

The goals of this project were to develop a high-biomass-content thermoplastic polyester blend for window panels and steering-wheel bezels using biomass-based PETG -- reportedly the first application in the world.  The optimized PETG/ABS composition was used to replace a PC/ABS blend. Benefits include a 57% reduction in carbon emissions (145 tons/year), an 88% reduction in VOCs, and a significant increase in molded part chemical resistance. By weight, the biomass content is 25% and by C14, the biomass content is 14%.

OEM/Vehicle Hyundai Motor Group 2015 IONIQ System Supplier Seoyon E-Hwa Interior Systems Manufacturing Material Processor    Seoyon E-Hwa Interior Systems Manufacturing

Material Supplier SK Chemicals Resin PETG/ABS SKYTRA Bio Polyester

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

Floorboard with Low VOC Emission Resin

High-VOC balsa wood cores (from rainforest trees with supply issues as well as variable density and performance) were replaced by low-VOC reclaimed PET foam cores to produce compression molded sandwich-panel composite floorboards. Weight was reduced with no loss of rigidity. NVH values were improved, eliminating the need for a secondary acoustic barrier. Additionally, a low-VOC vinyl ester resin system, which was compatible with the PET cores, was developed for panel skins. The resulting system passes export VOC emissions requirements, reduces cabin odor, diverts material that otherwise would be landfilled, and provides more consistent panel properties.

OEM/Vehicle General Motors Co. 2016 Chevrolet Corvette System Supplier Molded Fiber Glass Companies Material Processor    MFG Composite Systems Company

Material Supplier Reichold

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Electrical-System/Switches-Sockets.html?css=print

V6 Engine Timing System Wear Faces

By using injection molded PA 4/6 with a second proprietary polymer to increase surface hardness, contact wear (via chain intrusion into the plastic) was reduced on the wear faces of engine timing systems.  Rotational friction torque (measured at the crankshaft) was reduced more than 1 Nm, improving fuel-reduction targets without any modifications to the engine block or system layout. Other benefits include greater durability, lower noise, and less frictional loss. Furthermore, cost was reduced more than 50% vs. competitive alternatives.

OEM/Vehicle FCA US LLC 2016 Pentastar V6 Engines System Supplier Borg Warner Inc. Material Processor    Century Mold Co, Inc.

Material Supplier DSM Engineering Plastics Resin Stanyl® HGR1 PA46 Tooling/Equipment Supplier Century Mold Co, Inc.

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Electrical-System/Connectors.html?css=print

Closed-Loop Recycling of Bottles

This innovative, multi-stakeholder, cost-neutral recycling project protects the environment, grows local economies, creates jobs, and helps people in a sustainable manner. Water bottles collected at GM operations and from the Flint, Michigan area are directed into a supply chain that recycles the material into nonwoven fleece for specific applications including engine manifold cover insulation, insulation for coats that convert to sleeping bags for the homeless and are made by formerly homeless women as part of a jobs program, and air filters that purify the air at numerous GM and other manufacturing operations. Already 3.5-million water bottles have been repurposed.

OEM/Vehicle General Motors Co. 2016 Chevrolet Equinox, GMC Terrain System Supplier Exo-S Material Processor    Rogers Foam Co.

Material Supplier Wm. T. Burnett & Co. / Palmetto Synthetics LLC Resin Polyester

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Electrical-System/Lighting-Systems.html?css=print

PCR Cam Cover

This is the first time a 100% post-consumer recycled PA 6/6 resin with 33% short-glass reinforcement has been used for a demanding cam cover application to replace die-cast aluminum.  The PCR PA 6/6 offered excellent weldability to attach a high-efficiency air-oil separator and was molded in very-thin walls (to 2.0 mm for the Nano-model cover).  The result is a part that is 30% lighter than incumbent aluminum, offers lower NVH values and a 20% material cost reduction vs. virgin resin, and diverts carpet from landfills.

OEM/Vehicle Ford Motor Co. 2015 Nano 2.7L and 3.5L IVCT GTDI engines System Supplier ElringKlinger North America, Inc. Material Processor Bruss North America Inc.

Material Supplier Wellman Advanced Materials Resin EcoLon GF1960 PA66 (100% PCR)

For More Information See: http://www.plastics-car.com/Recycling/Life-Cycle-Use-Phase-of-a-Cars-Life?css=print

Underbody Aero Shields

In this application, underbody shields using virgin glass/PP LWRT composites were replaced by a material made from PET fibers, half of which were sourced from recycled water bottles. The result was lower cabin noise/better acoustics, better thermal performance, a 2% cost savings, and a more environmentally responsible solution.

OEM/Vehicle Ford Motor Co. 2016 Ford Fusion System Supplier US Farathane Corp. Material Processor US Farathane Corp.

Material Supplier US Farathane Corp. Resin PET fibers Tooling/Equipment Supplier US Farathane Corp.

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

Short-Glass/PP Replacement for Long-Glass/PP

In this application, a glass and mineral-reinforced PP copolymer containing 65% post-industrial recycled scrap polymer was used to replace a virgin long-glass PP with no loss in performance and no tooling changes. A battery of tests showed the new recycled short-glass/mineral PP had comparable mechanical performance to the incumbent virgin long-glass PP while providing environmental benefits and saving $2-3 USD/vehicle.

OEM/Vehicle Ford Motor Co. 2015 Ford F150, Ford Escape & Ford Fusion System Supplier Summit Polymers, Inc. Material Processor Summit Polymers, Inc.

Material Supplier TMG Automotive Resin Optipro CP2510GM GF PP

For More Information See: http://www.plastics-car.com/Plastics_101/Assignments?css=print