Volt Battery Impact Shield

This low cost, simple crash barrier protection shield boasts rapid development and implementation with innovative materials and molding. Six parts were molded together as one mold, requiring calculating the materials reaction when secondary waterjet cuts out each piece. Three composite material constructions were tested (polypropylene with 40%, 50% then 60% glass) while tooling and 12 sets of prototype parts were developed over a 6 week period. A test vehicle was crashed, with production intent parts, passing all

test criteria the following week. Production tooling and fixtures were also completed during that time (week 7). Full production was initiated in week 12. A 75% mass and 60% cost saving vs traditional high strength steel stamping with metal fabrication was achieved.

OEM/Vehicle General Motors 2017 Buick Enclave System Supplier CSP Teijin Material Processor    CSP Teijin

Material Supplier Quadrant Plastic Composites Resin GMTex X103F61-4/1-0/90° PP Tooling/Equipment Supplier Laval Tool and Mould

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

Energy Absorbing Collapsible Glove Box Bin

This bin, that holds and stores the owner's manual, collapses during impact to prevent severe femur loads while providing a beautiful flocked appearance. The new design provides a 400 gram weight savings while lowering femur loads from unacceptable to 5-star compliant. The support structure is injection molded with a
compressed PET internal shell. This 100% recyclable, patent pending, concept can be used on any vehicle line to address high femur load issues and assist in achieving a 5-star crash rating.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition System Supplier Detroit Manufacturing Systems Material Processor    Detroit Manufacturing Systems

Material Supplier Advanced Composites Resin Basell - SG702 PP Tooling/Equipment Supplier Lamko Tool & Mold

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

All Plastic Hood Leveler

This industry first all plastic hood leveler helps to manage pedestrian hood/ head impact to reduce head trauma. It features a light weight design, OEM snap-in quick assembly, preset and adjustable height, and is recyclable. A 50% weight savings and a 35% cost savings is estimated compared to current steel/plastic/rubber hood levelers. The snap-in base is Acetal for a strong snap feature and no squeak against the Nylon post. The threaded post is nylon for strength and low moisture dimensional influence. The over-molded bumper is TPE for no squeak on the inner hood and additional energy management. The interaction of the three chosen polymers allow for required use of their individual properties and also the collaborative energy management response as they work together to help reduce head impact trauma from beneath the hood inner upon a low speed pedestrian contact.

OEM/Vehicle Ford Motor Company 2018 Lincoln Navigator System Supplier MacLean-Fogg, Engineered Plastic Components, Inc. Material Processor    MacLean-Fogg, Engineered Plastic Components, Inc

Material Supplier DuPont Automotive, ExxonMobil Resin Zytel 70G33 PA66, Delrin 100 POM, Santoprene SA60 TPE Tooling/Equipment Supplier Elite Tool & Die

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

D Pillar

This is an Industry-first use of a polycarbonate copolymer material on a D Pillar. Improved impact performance vs. PMMA was achieved and it allowed for rivet attachment to the vehicle without failure during environmental testing. The material demonstrated good UV, heat, and gloss performance. The material change also made it possible to achieve a high gloss piano black mold-in-color to OEM standards.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition System Supplier Windsor Mold Group Material Processor    AUTOPLAS

Material Supplier SABIC Resin LEXAN SLX 2271T PC Copolymer Tooling/Equipment Supplier Windsor Mold Group

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

Paint Racks with Robber Bars for Electrostatic Paint Line

This painting process uses racks with “Robber Bars" to attract paint and reduce over-spray on the backside of the plastic part during the painting process (generating squeak issues). The bars on the backside of the racks attract the paint of the electrostatic paint line and help to prevent over-spray, reducing VOCs due to less use of paint and eliminating the need for the manual masking process. This results in a cost save of $.24 per vehicle and can be translated to all electrostatic paint lines for plastic components.

OEM/Vehicle Ford Motor Company 2018 Ford Fusion System Supplier Flex-N-Gate

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

Torsional Welding of PDC Sensors to Thin Wall Fascia

This is the first application of torsional welding (spin & ultrasonic welding combined) on automotive fascias. It allows welding of PDC brackets without localized thickening of wall stock on 2.5 mm, thin wall, molded fascias. An adjustable TPO material with high melt flow, high stiffness/ impact allowed for less material to be used resulting in a 10% reduction in mass for a 7% weight savings with $122,000 direct cost savings in three years. Cycle times were improved and there was no weld read through resulting in a quality appearance. Future applications or this process include fascia support brackets, fog brackets and more.

OEM/Vehicle Volkswagon AG 2018 Skoda Octavia System Supplier Magna Exteriors Material Processor    Magna Bohemia Liberec

Material Supplier SABIC Resin Sabic 8650 TPO Tooling/Equipment Supplier Changzhou Huawei Mold Co., Ltd.

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

Integrated Sliding Armrest and Hinge Assembly

Additional console stowage volume with a lid held open to any position (like a laptop screen) is achieved with this single Injection molded upper bin and lid inner using a torque insert to create hinge for the armrest. It includes Integrated attachments for a sliding armrest that is interchangeable with a fixed armrest. Using a robotic arm, the torque insert hinge is placed into the cavity of the mold and over-molded with 30% glass-filled nylon 6. Upon mold close, the seal off around the hinge allows for the upper leaf and lower bin to be independently injected at the same time (using sequential valve gating), producing 2 complete assemblies in one press cycle. This eliminates the need for metal hinge systems saving $4.50 and 2 lbs weight per unit

OEM/Vehicle Ford Motor Company 2017 Ford EcoSport System Supplier Faurecia Interior Systems Material Processor    M & N Plastics

Material Supplier BASF Corporation Resin Ultramid B3EG6 30% GF PA 6 Tooling/Equipment Supplier M & N Plastics

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

Winged Spring Clip with 4 Way Locator

Metal clips and springs were eliminated by designing an in-molded W shaped plastic clip with a 4-way locator providing efficient attachment per requirements and eliminating additional costs for fasteners and assembly. The plastic part comes out of the tool with the clips molded in. The patented winged spring clip design locates, locks and retains in a single snapping action. A cost save of $0.17 per clip/$2.19 per vehicle resulting in $250K per year; and a 10% weight saving is achieved.

OEM/Vehicle Ford Motor Company 2018 Expedition/Navigator System Supplier Magna Seating Material Processor    Royal Technologies

Material Supplier Advanced Composites Resin ADX 5017 TPO Tooling/Equipment Supplier Tri Tech Tooling, Inc.

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

Part via Preform (PVP) Assembly Carrier

Part via Preform (PvP) technology enables economical production of carbon fiber reinforced plastic (CFRP) automotive parts. The carbon fiber has been binder-modified to be sprayed into near-net shape preforms without intermediate textile processing resulting in a 30% cost save. High fiber volume content (50% Vf), delivers high mechanical properties. The process can create complex shapes with homogenous material and can be combined with aligned fiber placement (AFP) for part reinforcement. Resin injection of PvP preforms works with high pressure resin transfer molding (HP-RTM) including an inmold coating step to provide for easy surface painting. The binder on the carbon fiber can be activated, allowing for greater design freedom, and ability to assemble preforms and achieve local thickness variations to exacting specs.

OEM/Vehicle Volkswagon AG 2016 Porsche GT3 Cup II System Supplier Toho Tenax Material Processor    Toho Tenax

Resin Epoxy

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

Engine Coolant Control Valve

This unique product design allows good fluid control and low coolant leakage at the seals on the valve moving components. Dimensional control is provided through innovative molding and assembly processes with the combination of PPA and PPS materials. A 1 lb weight savings and 20% cost savings is achieved, compared to a metal part. An approximate 2% increase in fuel efficiency and reduced emissions result in a reduced carbon foot print.

OEM/Vehicle FCA US LLC 2016 GME-T4 (Alfa Romeo - Guilia/ Stelvio) System Supplier ITW Powertrain Components Material Processor    ITW Powertrain Components

Material Supplier Dupont Automotive Resin Zytel HTN 51G35HSLR BK420 PPA

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

Transmission Baffle

Unique part geometry and CFD (Computational Fluid Dynamics) studies led to the design of this new baffle for injection molding enabling seal elements and fluid flow passages for improved transmission performance - not possible before in a stamped metal component. Transmission efficiency was improved by 8% resulting

in up to 0.5 mpg economy. A reduction of 50% in weight and 40% in cost ($1 per transmission) was gained compared to a metal part with molded seal elements. The TPE material is recyclable reducing its carbon footprint.

OEM/Vehicle Ford Motor Company 2018 Ford Focus System Supplier Ford Material Processor    Toledo Molding and Die

Material Supplier Dupont Automotive Resin Hytrel 7246 TPE Tooling/Equipment Supplier Toledo Molding and Die

For More Information See: http://www.plastics-car.com/s_plasticscar/fuel_economy/Default.html

Carbon Fiber Torque Tube

This CFRP torque tube is unique in its performance, complexity, dimensions and manufacturing process and has been developed for extreme lightweight construction and vehicle performance. Extreme lightweight construction (-40%), highest stiffness and NVH performance, high safety reserves, temperature load up to 200 degrees, and monolithic implementation of the complex structure in a one-shot production step. It was produced with a new process (first time in auto industry) that is a combination of resin transfer molding and a process from blow molding flexible tubes. The component was inflated in the interior of the tool by vacuum and overpressure. The injection from the resin takes place from the outside.

OEM/Vehicle Mercedes-Benz GmbH 2017 Mercedes AMG GT R System Supplier ACE Advanced Composite Engineering GmbH Material Processor    ACE Advanced Composite Engineering GmbH

Material Supplier Huntsman Resin Huntsman 8625 epoxy

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

Intake Manifold with 2-Shot Molded Power Valve

This air intake manifold blade was made via a 2-shot molding process overmolding a thermoplastic polyester elastomer over a 36% mineral filled nylon 66. in the same tool. The previous process required two suppliers - one to injection mold the nylon portion of the blade and another to compression mold a rubber-FKM surround requiring additional assembly. This new process resulted in a 33% direct part savings and additional freight and transit savings using one location to manufacture the part in place of three

OEM/Vehicle FCA US LLC 2017 Dodge RAM System Supplier MAHLE Filter Systems Material Processor    MAHLE Filter Systems

Material Supplier Dupont Automotive Resin Hytrel 3078 HS BKB320 TPC-ET Tooling/Equipment Supplier MGS Mfg. Group

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

High Elongation Fabric

This high elongation PVC coated fabric is formulated and designed for wrapping tight radius parts with no texture lost or deformation. It is designed to support a variety of applications including seating, headrests, map pockets, consoles, doors and instrument panels. This high stretch material provides a leather like look and feel in any color, accommodates high strain without tearing making it easy to implement stitching applications, and meets sun load requirements. The estimated cost is $2 USD a sq. ft. less than leather.

OEM/Vehicle Ford Motor Company 2015 Ford MKC System Supplier International Automotive Components (IAC) Material Processor    International Automotive Components (IAC)

Material Supplier CGT Resin PVC Tooling/Equipment Supplier CGT

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

Grained Roof Ditch Moldings

Usually, a grain appearance in extruded parts is achieved via embossing rollers confining the look to the top surface of the part only. This unique PVC material development has the grain in the material enabling a grain appearance throughout the part, including the sides of the extrusion, without secondary operations required. This enables greater styling options for interior and exterior part designs at less cost. A 10% direct cost savings is associated with this innovation through process efficiency and lower equipment maintenance costs. Approximately $30K cost avoidance savings annually is directly associated with this innovation. it is scratch and mar resistant, weatherable, co-extrudable and it also bonds to metal.

OEM/Vehicle General Motors 2017 GMC Sierra, Chevrolet Silverado System Supplier Martinrea International Material Processor    Martinrea International

Material Supplier Teknor Apex Resin Apex 85 - J438N Black 621 PVC Tooling/Equipment Supplier Rollstar Metal Forming

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