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

Gen-3 4-way Head Restraint

This low cost, low mass, head restraint provides exceptional rigidity for whiplash protection. Its flexible design allows the front surface of the head restraint to be translated closer to or further from the occupant by 60 mm without incurred costs (allowing for the precise balancing of comfort and safety). Using plastic, in place of steel, as the primary load bearing component is new to front row head restraints. The part design eliminates manufacturing complexity making use of intelligent geometries so that readily available materials could be used. A $10.73 Million savings ($2.80/vehicle) is projected by the end of MY2020.

OEM/Vehicle Ford Motor Company 2018 Ford F150 System Supplier Windsor Machine and Stamping Material Processor    Windsor Machine and Stamping

Material Supplier Ravago Resin Hylon N1000STHL PA Tooling/Equipment Supplier Integrity Tool & Mold

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

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

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

Two Shot Interior Decoration Bezel

This unique 3-D decorative effect was achieved with 2K 'reverse' injection molding (1st shot tinted PC) with overmolding of grained surface with 2nd shot (self colored pigmented ABS). This is the first time this process was used to achieve the 3-D visual effect (color and texture) for a part of this size and geometry. A 30% cost save was achieved vs IMD/IML/high gloss painting and there was a 20% scrap reduction vs conventional 2-layer high gloss piano black appearance.

OEM/Vehicle Ford Motor Company 2018 Ford Fiesta System Supplier Faurecia Interior Systems Material Processor    Faurecia Interior Systems

Material Supplier Lotte Advanced Materials Resin INFINO LT1220 PC Starex LX0760 ABS Tooling/Equipment Supplier JP Grosfilley SAS

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

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

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

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

Low Friction Polymer for Chain Tensioner Arms

This usage of a modified PA46 resin to enhance stiffness, on vehicles powered by a 5.0L V8 engine, was a drop- in replacement for PA66, for enhanced wear and friction performance. The resultant fuel economy savings (0.4%), from rotational torque reduction in the cam-shaft (0.5Nm), was equivalent to a 40lb weight reduction, and at 1/10th the cost. Annual environmental benefits include reductions in gas consumption by 12,000 Barrels and green-house gas emissions by 5,000 Tons. This innovation is highly translatable, to provide affordable fuel economy improvement, and will be utilized on more Ford vehicles, beginning in 2018. The total potential environmental impact of translations, at Ford, may be multiple times the values noted for the Mustang and F-150.

OEM/Vehicle Ford Motor Company 2017 Ford F150 / Mustang System Supplier Borg Warner

Material Supplier DSM Resin Stanyl HGR2 PA46(+PTFE)

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

Non-weakened Skin for Seamless Airbag System

This scoreless skin technology eliminates the visible line of the airbag door. A special bi-laminate foil with TPO chemistry for unique tensile, shear and processing characteristics enables an improved surface appearance over previous scored IP skin constructions. Parts are injection molded with inmold lamination. No high capital expenses ($750,000 cost avoidance) for laser score equipment make this doable globally in low cost, low tech countries. The previous process included injection molding the substrate, cutting and sewing and hand wrapping the top skin cover and laser scoring the composite panel. Streamlining the production results in a $1.5/part cost saving. Since the skin is not weakened by scoring, the underlying substrate can be made weaker to enhance the airbag deployment door opening time.

OEM/Vehicle Ford Motor Company 2018 Ford EcoSport System Supplier Faurecia Interior Systems Material Processor    Faurecia Interior Systems

Material Supplier Haartz Resin Deploy Bilaminate TPO Tooling/Equipment Supplier GS Engineering

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

Squeak Resistant IP Cluster Bezel

This IP cluster was molded with a new, patented low gloss ABS resin that provides parts with a markedly lower coefficient of friction that eliminates squeak and “stick/slip” noises caused by interior components in a vehicle. 22 pieces of felt, 16 Mylar tapes and grease were eliminated in assembly resulting in cost savings of $1.62 per vehicle. There are 9 commercialized applications in North America resulting in $4 Million annual savings. This new material offers "no squeak" properties, drop in usage (replaces general purpose ABS without need for tooling modifications), high flow for larger more difficult to mold parts, and is not additive based. Low gloss appearance eliminates need for painting.

OEM/Vehicle Ford Motor Company 2016 Ford Mustang System Supplier Summit Polymers Material Processor Summit Polymers

Material Supplier Techno Polymer America Resin HUSHLLOY HS301 ABS

For More Information See: http://www.plastics-car.com/Automotive-Group/Sponsored-Projects-and-Industry-Issues

Carbon Fiber Filled PP

Using recycled carbon fiber filled polypropylene, (changed from ASA) and changing soft material from TEA to TPE, creating a new material specifically for this "A" pillar bracket, resulted in a 14% weight reduction and $186,158 yearly cost save (300,256 volume). Significant CLTE reductions were also achieved. The rigid portion of the material is designed to fit existing tooling, and be compatible with the new soft material resulting in a new hard/soft material system for more cost effective carbon fiber based applications for exterior and interior trim parts. The carbon fiber is recycled from various sources including airplane bodies and bicycles.

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

Material Supplier Borealis Compounds Inc Resin Fibermod CB061SY PP

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

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