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

Carbon Core Structural Components

Carbon fiber-reinforced fast-cure epoxy and high-pressure RTM and liquid compression molding (LCM) are used to produce 27 CFRP parts for the vehicle's mixed-material BIW structure to support production volumes of 80,000+ vehicles/year. The HP-RTM roof arc follows the shapes of the car body and offers an outstanding weight/performance ratio. The LCM tunnel reinforcement improves the vehicle's torsional stiffness and is produced in <1 min. These "carbon core" parts replace metal, improve stiffness, ride/handling, and safety while reducing vehicle mass 40 kg for better fuel efficiency and tailpipe emissions.

OEM/Vehicle BMW Group 2015 BMW 7 Series Sedan System Supplier BMW AG Material Processor    BMW AG

Material Supplier Hexion Inc. Resin EPIKOTE/EPIKURE Epoxy

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

TPO-Coated Suspension Arm

By using a cryogenically ground TPO powder coating to protect e-coated steel suspension arms instead of paint, service life is extended from 3-5 years to a decade, the fully encapsulated part gains improved stone-chip resistance and corrosion protection. Overspray can be reused, so the process generates almost zero waste, eliminates VOCs and isocyanates, and produces finished parts much faster than previous alternatives. Since there is no need for a post-bake process, it also saves energy. Thinner gauge, high-tensile steel is used for the suspension arms to save weight.

OEM/Vehicle General Motors Co. 2015 Cadillac ATS System Supplier Cymas Enterprises Ltd. Material Processor    Cymas Enterprises Ltd.

Material Supplier LyondellBasell Resin 7905 TPO

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

Precise Integration Enabled System

The precision integration-enabled system is a patented locating and attachment feature that minimizes gaps or movement as well as manufacturing variation common with snap fits while leveraging the inherent elastic deformation properties of plastic.  No external fixtures are needed, labor is reduced, and ergonomics are improved. This is the first application to use a MIC bezel for the housing that prevented water migration without need for additional seals. Also, the typical tooling action needed to mold snap fits was eliminated, saving tooling time and costs.

OEM/Vehicle General Motors Co. 2015 Chevrolet Volt System Supplier ITW Deltar Material Processor    ITW Deltar

Material Supplier Celanese Corp. Resin MetaLX Hostaform POM Tooling/Equipment Supplier ITW Deltar

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

3D Flocking Tape on Inner & Outer Belt

This 3D flocking tape cell applies flocking tape to the bi-injected TPE/PP outer belt using a 6-axis robot. For optimal performance, the process requires multiple adjustments, including speed, contact pressure, heat, and proper guidance. It is able to meet general tolerances of ± 1 mm and CLD client requirements. Benefits of the process include reduction of secondary operations, eco-friendly recyclable part, design flexibility vs. extrusion, reduction in weight (10-15%) and cost (≈25%), reduction of labor, and cosmetic and performance improvements. The flocking tape facilitates sliding across 3D parts.

OEM/Vehicle PACCAR Inc. 2015 Kenworth System Supplier Hutchinson Group Material Processor    M.I. Integration

Material Supplier Rhetech / ExxonMobil Chemical Resin Rhetech T20P100 PP Santoprene 121-70M350 TPV Tooling/Equipment Supplier M.I. Integration

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

Active Fuel-Management System

To boost fuel efficiency and reduce emissions on classic small-block pushrod V8 engines, an inexpensive and simple technology called active fuel management (displacement on demand) was developed. The efficient and precise electro-mechanical hydraulic system deactivates cylinder valves when power is not needed, then reactivates them when power is called for again. An important component of the system's solenoid control valves is injection molded, 30% GR-PEI, used for its high stiffness, creep resistance, thermal and chemical resistance, high knitline strength, and ability to be ultrasonically welded. The system improves fuel efficiency 5.5-7.5% and reduces cost 30% vs. metal.

OEM/Vehicle General Motors Co. 2012 5.3L V8 LH6 Engine System Supplier Eaton Corp. Plc. Material Processor    ITW Global Automotive

Material Supplier SABIC Resin ULTEM 2310 PEI

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

Air Intake Manifold

This is the first air-intake manifold launched in China using 35% GR-PP to replace PA 6/6. The application provides 25-30% cost reduction and 15-20% molded-part weight reduction while retaining properties at high temperatures and improving weld strength, and NVH by 5 dB. Unique technology involving finer glass fibers and special sizing helps meet performance requirements. Parts are vibration welded.

OEM/Vehicle Volkswagen AG 2015 EA21 Engine  1.6L engines System Supplier Hua Tao Ltd Material Processor    Hua Tao Ltd

Material Supplier SABIC Resin SABIC G3135X PP

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

Torque-Tube Bearing Spacer

This metal-to-plastic conversion of a torque-tube bearing spacer provides significant weight savings to the drivetrain. The injection molded 50% long-glass PPA material eliminates machining on previous cast housings, provides high stiffness and low creep, outstanding impact resistance, high temperature performance, and holds ID and OD tolerances of +/- 50 microns. It also reduces mass 80% and costs 40-60%. Further, the composite spacer improves serviceability/rework and eliminates galling on the torque tube.

OEM/Vehicle General Motors Co. 2015 Buick Envision System Supplier American Axle & Manufacturing, Inc. Material Processor    NN Industrial Molding

Material Supplier DuPont Automotive Resin Zytel® HTN51LG50HSL BK083 PPA Tooling/Equipment Supplier HS Molds Ltd.

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

Window Frame Surround

To meet window-frame surround requirements for high stiffness, low gloss, good surface quality and haptics, colorability with good processability, high scratch and UV resistance, and dimensional stability, a new 25% GR-TPO compound was developed to replace 15% GR-PA 6. The new grade offers higher stiffness, which facilitates thin-wall part design. It does not require drying prior to processing and its properties are not affected by ambient changes in humidity. The result is an 8% weight savings and ≈18% piece-cost savings.

OEM/Vehicle Daimler AG 2015 Mercedes-Benz GLC, GLC Coupe & E-Class System Supplier Dr. Schneider Automotive Group Material Processor    Dr. Schneider Automotive Group

Material Supplier LyondellBasell Resin Softell TKG 317N PP Tooling/Equipment Supplier Krumpholx

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

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

Energy-Absorbing Armrest

An open design with a flexible, yet durable cover replaced conventional molded slots or honeycombs in this injection-molded armrest, improving vertical load performance and side-impact energy absorption. In addition to boosting performance, durability was also increased 3.5 times on this police special vehicle.

OEM/Vehicle Ford Motor Co. 2015 Ford Explorer System Supplier Yanfeng USA Automotive Trim Systems Inc. Material Processor Yanfeng USA Automotive Trim Systems Inc.

Material Supplier MRC Polymers Resin PP Tooling/Equipment Supplier Yanfeng USA Automotive Trim Systems Inc.

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

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

Direct Fascia-Mounted Sensor

A flexible pedestrian-protection crash sensor bracket injection molded in plastic with an embedded metal stud is sonically welded directly to the fascia skin to decrease signal noise and improve response time of the deployable hood system. The flexibility of the design helps the bracket to conform to different fascia contours, allowing for a single bracket design to be used in multiple locations on the same vehicle, or across different vehicle lines. The final design saved 1 lb and $5 USD/vehicle and allows the hood to deploy faster for greater pedestrian safety.

OEM/Vehicle Ford Motor Co. 2015 Ford Mustang System Supplier MacLean-Fogg Co. & Ford Motor Co. Material Processor MacLean-Fogg Co.

Material Supplier LyondellBasell Resin Hifax 852X TPO Tooling/Equipment Supplier Industrial Automation LLC.

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