Floor Rocker Reinforcement

An optimized MPPE/PA 6 honeycomb geometry in a plastic/metal hybrid proved to be a very efficient energy-absorbing crash-box structure in this floor rocker reinforcement. Not only is the component E-coat capable, but it is very easy to assemble into the vehicle's BIW. Since the plastic honeycomb is integrally attached to 2 steel flanges during injection molding, no structural adhesives are needed. The mixed-material solution took 1 kg of weight out of the BIW, saved approximately 10%, and contributed tooling savings vs. previous steel solutions.

OEM/Vehicle FCA US LLC 2015 Jeep Renegade System Supplier Proma Group Material Processor SABIC

Resin NORYL GTX 910 PPE/PA Tooling/Equipment Supplier Redstamp

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

Rear Lamp Reflector

Rear lighting plays an important safety and branding role. New lighting technologies have been combined with plastics to create innovative new designs, such as this rear lamp with unique lit and unlit appearance. The system uses high specular and diffuse reflection from multiple LEDs to create a homogeneous light glow. Thanks to a special color additive, the white polymer's high reflectivity after molding and heat aging, and minimal color shift eliminates the need for direct metallization or painting. Injection molding also enables design features like clips to be integrally molded close to LED circuit boards.

OEM/Vehicle FCA US LLC 2015 Dodge Challenger System Supplier Varroc Lighting Systems Material Processor Varroc Lighting Systems

Material Supplier SABIC Resin LEXAN™ LUX 2289 PC

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Brake Booster Water Shield

This brake-booster water shield provides a water-tight cover without compression or adhesive, protecting the weld seam from water intrusion and possible corrosion. A working prototype was developed within 14 hours off a wax casting tooling, and production parts were installed on vehicles within 7 weeks. Cross-linked PP, which is vacuum formed and die cut in a single step, also provides NVH reduction and enabled the brake-booster housing to be changed from steel to aluminum, providing cost and weight savings.

OEM/Vehicle FCA US LLC 2016 Jeep Grand Cherokee System Supplier Continental Teves, Inc. Material Processor Unique Fabricating, Inc.

Material Supplier Sekisui Voltek, LLC Resin XLPP Tooling/Equipment Supplier Unique Fabricating, Inc.

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