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

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

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

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

Battery Enclosure Cover

The battery pack is a stressed member and weighs 960 lbs/440 kg. It accounts for 23% of the car's value. The SMC cover is a large light weight cover that is integral to the pack. A new light weight high glass loaded Vinyl ester/Polyester blend SMC was formulated to meet the high speed stress strain requirements and, for the first time, be incorporated as part of the structural element. A 30% weight savings and a 40% cost savings, over alternative manufacturing methods (steel/aluminum stampings) was achieved.

OEM/Vehicle General Motors 2017 Chevrolet Bolt System Supplier LG Electronics Material Processor    Hanwha Corporation

Material Supplier Hanwha Corporation Resin 5145 SMC vinyl ester/ polyester Tooling/Equipment Supplier Hanwha Corporation

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

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

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

Closed Loop Plastics & End-Of-Life Resin Use

Folding seat modules and plenum ducts are being produced with recovered 100% PCR PET resin from water bottles from CAMI Assembly Plant. The Lavergne Group Inc. has worked with GM CAMI Assembly Plant’s Global Environmental Compliance and Sustainability - Canada Region to implement the bottle collection program at the Lavergne facility. The recycled PET plastic is washed, flaked and turned into pelletized sustainable engineering resins. Bottle collection started in February 2017. This project is a demonstration of circular economy, bringing water bottles from CAMI, a landfill free, zero waste operation, processing them and returning those bottles in the form of a component to the same plant that generated the bottles.

OEM/Vehicle General Motors 2017 Chevrolet Equinox, GMC Terrain System Supplier Windsor Mold Group Material Processor    Windsor Mold Group

Material Supplier Lavergne Resin VYPET VNT 835 35% GFR, PCR, PET Tooling/Equipment Supplier Windsor Mold Group

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

Powertrain Mounting Clevis Bracket

This engine clevis bracket is the first composite mount designed for a 6 cylinder engine, and passing peak loads of 25 Kilo-newtons of force. The injection molded part replaces metallic solutions (stamping, welding and die-casting) used previously resulting in a 45% weight save. NVH was also improved (reduction in cabin noise) due to the damping characteristics of the polyamide compared to aluminum. Corrosion resistance is improved and the part can be recycled at end of life. Seven clevis brackets were developed for different powertrain combinations and there are no warranty claims after 1.5 years of production

OEM/Vehicle General Motors 2017 Cadillac XT5 System Supplier Hutchinson

Material Supplier BASF Corporation Resin Ultramid A3WG10 CR BK00564 PA66+50%GF

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

Door Edge Protector

This industry first door guard system protects all doors from dings and scratches - and neighboring vehicles as well. The door guard is not visible until it articulates out upon opening of the door. Parts are injection molded and no metal fasteners are needed. This is a marketing feature add on of $100/vehicle offering an estimated $500K warranty savings per year.

OEM/Vehicle Ford Motor Company 2017 Ford Fiesta System Supplier Witte Automotive Material Processor    Witte Automotive

Material Supplier Washington Penn Resin H2TF-2B PP Tooling/Equipment Supplier Witte Automotive

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

Plastic Clip for Door Integrated Window Regulators

These industry first plastic clip attachments secure the IWR mechanism to the side doors (46 clips/vehicle). They replace metal fasteners and weld nuts for a weight savings of .44 lbs per vehicle. Estimated cost savings include $350K for reduced cycle times, $210K for scrap cost elimination and $250K per plant as no tools are required. Customer benefits include improved fuel efficiency, better crash performance (energy absorption) due to the flexibility of the carrier, improved NVH and acoustic performance of the doors.

OEM/Vehicle Ford Motor Company 2017 Ford Fiesta System Supplier Brose Material Processor    Brose

Material Supplier Omni Plastics Resin Omni Lon 6/6 PA66 Tooling/Equipment Supplier A. J. Raymond

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

Engine Bracket

Utilization of a 50% glass reinforced polyamide for engine brackets enabled improved NVH in the powertrain. An innovative injection molding tooling concept with 1 +1 tooling (including hot runner and pressure transducer for continuous process control for both the left and right side bracket) was developed for production. This is the first time two cavity tooling with a hot runner system plus two pressure transducers for each cavity, enabling the continuous monitoring of the process, have been utilized. A cost savings of, up to 20% compared to metal brackets and up to 15% compared to aluminum brackets, was achieved.

OEM/Vehicle Daimler AG 2017 E-Klasse Coupé System Supplier ElringKlinger Material Processor    ElringKlinger

Material Supplier Dupont Automotive Resin Zytel 70G50 HSLA PA 66 GF50 Tooling/Equipment Supplier HummelFormen

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

Instrument Panel Carrier

Long glass fiber PP injection molding via structural chemical foaming with core-back process enabled the production of this part with very low VOC emissions, meeting VDA 278 specification. Extensive CAE work predicting warpage of the foamed part provided valuable insights, allowing for the modification of tooling in advance. Use of foaming means less material is required resulting in a 15% weight savings, fewer emissions and less cost.

OEM/Vehicle BMW 2017 Countryman System Supplier International Automotive Components (IAC) Material Processor    International Automotive Components (IAC)

Material Supplier SABIC Resin Stamax PP LGF Tooling/Equipment Supplier Siebenwurst

For More Information See: http://www.plastics-car.com/Partners/Colleges-and-Universities

Real Wood Interior Door Garnish Using Natural Cork

This is the first real wood film and parts technology using natural cork. It is eco-friendly not requiring cutting down trees (cork is harvested from the bark of living cork oak trees every ten years). It is more costcompetitive than conventional wood parts because of its simple structure and manufacturing process. Conventional wood parts are a multilayered structure using several layers of wood veneer and require 20 steps of complex molding and machining including milling. Cork wood film is made with lamination equipment and parts are processed via insert injection molding. A 24% weight and a 65% cost savings is achieved compared to wood. Cork’s unique honeycomb-structure offers elasticity, insulation and sound proofing.

OEM/Vehicle Hyundai Motor Company 2017 Grandeur Hybrid System Supplier Seoyon E-Hwa Interior Systems Material Processor    Seoyon E-Hwa Interior Systems

Material Supplier L & J Resin ABS Tooling/Equipment Supplier Seoyon E-Hwa Interior Systems

For More Information See: http://www.plastics-car.com/Plastics_101/QuizzesExams

Thin Wall Floor Console Carrier

This floor console carrier is unique with its 2.0 mm nominal thin wall thickness (with ability to implement lightening holes) and 40% Long Glass Fiber PP construction with first surface quality appearance. A 30% mass savings resulting in a 2.2 lb/.99 kg weight savings, and a 15% cost savings was achieved. Lateral stiffness targets were exceeded eliminating the need for metal brackets ($1.50). It is also the first time injection molding was used to process this type of a component.

OEM/Vehicle General Motors 2017 Buick Enclave, Chevy Traverse System Supplier NYX Material Processor    NYX

Material Supplier Celanese Resin Celstran 40-0453 PP GF Tooling/Equipment Supplier Integrity

For More Information See: http://www.plastics-car.com/Plastics_101/Assignments