Shaker Scoop

This structural component had to meet Class A body panel styling requirements, increase horsepower, reduce acoustics, mass, and cost, and meet all the fatigue, impact, environmental, and thermal requirements of air-induction system components and still be moldable. The resulting assembly is an important visual focal point of the vehicle, yet is approximately 65% lighter and 60% lower cost than die-cast aluminum.

OEM/Vehicle Fiat Chrysler Automobiles 2014 Dodge Challenger Shaker sports car System Supplier North American Assembly Material Processor Molding Technologies Inc.

Material Supplier Magna International Inc. Resin EB-323 Class A SMC Tooling/Equipment Supplier Penco Tool Inc.

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

Charge Air Cooler Duct and Resonator

A super-stabilized PA 4/6 resin is used to mold a combination hot-side charge air cooler duct plus resonator in a unique shape that accommodates a difficult packaging environment. Doing so eliminates 1 sub-component , delivering corrosion-free performance for longer life, improved captive screw retention, enables improved seal design and retention, reduces weight 32% and cost 42% vs. the metal predecessor.  It also allows the resonator to be incorporated as an insert for easier acoustic tuning and flexibility to use the same part in a similar package with different acoustic requirements.

OEM/Vehicle Fiat Chrysler Automobiles 2014 Jeep Cherokee SUV System Supplier Hutchinson FTS Material Processor Hutchinson FTS

Material Supplier DSM Engineering Plastics Resin Stanyl Diablo OCD2100 PA46 Tooling/Equipment Supplier Hutchinson FTS

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

Front and Rear Fascia

To meet new styling trends for fascias, a new lower density TPO with unique performance improvements was formulated. The material offers an excellent balance of stiffness and impact, easy flow and demolding, a broader process window, and shorter molding times. This resulted in approximately a 5% weight and a 3-5% cost savings.

OEM/Vehicle Fiat Chrysler Automobiles 2014 Jeep Cherokee SUV System Supplier Magna International Inc. - TEAM Systems Material Processor Magna International Inc. - Norplas

Material Supplier LyondellBasell Industries Resin Hifax TYC 1168 X/P TPO Tooling/Equipment Supplier Magna International Inc. - Tycos Tool & Die Div.

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

TPE Jounce Bumper

This is the first TPE jounce bumper that integrates several components into a single part to help deliver lower systems costs and better performance, including improved durability, noise, and mechanicals under demanding conditions such as low temperatures, high humidity, or high loads.  The use of an injection / blow molded TPE to replace injected foam polyurethane eliminates the need for metal or PA saturation cups due to better saturation height control, which in turn allows total suspension height to be reduced.  Additionally, 10% mass savings, shorter processing cycles, and lower systems costs were achieved.

OEM/Vehicle Fiat Chrysler Automobiles 2015 Fiat Punto supermini car System Supplier Insit Material Processor Insit

Material Supplier DuPont Automotive Resin Hytrel HTR8724 TPC-ET

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

Plastic Reinforcement for Truck Bumper

This is the first steel pickup truck bumper reinforced with an injection-molded composite support bracket. The part provides an excellent stiffness/weight ratio required for durability while reducing mass 4 lb / vehicle and yielding a small cost savings. Predictive engineering with advanced fiber-orientation modeling was used to properly set up the injection mold.

OEM/Vehicle Fiat Chrysler Automobiles 2014 Dodge Ram 1500 pickup System Supplier Flex-N-Gate Corp. Material Processor Flex-N-Gate Corp.

Material Supplier SABIC Resin STAMAX 30YM240 LFT-PP Tooling/Equipment Supplier Integrity Tool and Mold, Inc.

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

Hybrid Rear Bumper Beam

This is the first hybrid (plastic / steel) rear bumper beam that can travel through the OEM E-coat process. An unfilled, crushable MPPE/PA honeycomb that is hot-plate welded to a base plate is used to pass all relevant test specifications.  The part also provides support and fixation for the rear bumper fascia, while reducing mass 1.5 kg / 3.3 lb and cost 10%.

OEM/Vehicle Fiat SpA 2011MY Fiat Panda System Supplier Ben Vautier Material Processor RT Technologies

Material Supplier SABIC Resin Noryl GTX 910 MPPE / PA Tooling/Equipment Supplier Redstamp

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

Electric Power-Steering Flexible Coupling

This flexible plastic coupling for the vehicle’s electric power steering replaced a similar stainless-steel coupling with broached splines and grease. The part features ribs that connect and transfer torque from one rotating shaft to another, which in turn strokes axially and stretches and compresses the coupling. The fully compliant, constant-velocity joint eliminates torsional lash, the need for grease, and all sliding interfaces at a cost savings, while reducing audible cabin noise and improving steering “feel.” The system replaces traditional hydraulic systems, reducing weight 17%, cost 50%, increasing fuel economy by 4%, and improving system performance and customer satisfaction.

OEM/Vehicle 2010MY Fiat S.p.A.: Fiat® 500 Compact Car System Supplier Nexteer Automotive Material Processor Forteq

Material Supplier DSM Engineering Plastics Resin Stanyl® TW241F10 50%-GR PA 4/6

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Chassis-Design-NVH-Performance

Renewably Sourced PA for Biodiesel

This is the first automotive use of PA 10/10 and the first bio-based PA 10/10 application. It is used in a diesel fuel line replacing PA 12.  The bio-based resin provides superior temperature  and chemical resistance, as well as heat-aging performance in biodiesel fuel blends vs. PA 12. This specific composition also contains a minimum of 60% bio content by weight for a more sustainable solution.

OEM/Vehicle Fiat S.p.A. 2011 Diesel engines, various models System Supplier Hutchinson Material Processor Hutchinson

Material Supplier Dupont Automotive Resin Zytel RS 1610 PA 10/10

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