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

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

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

Turbo Charger Outlet T-Joint

A 42% weight and 35% cost reduction, and improved airflow reducing the pressure drop (-8kPa) to increase fuel economy and improve NVH performance was achieved by designing and molding this part with plastic compared to the previous aluminum die cast part. Air flow noise was also reduced and long term durability increased via the rib pattern design. Special 3-gate positioning tooling was designed to minimize stress in weld-line area for strength and durability and for processing optimization. A new 35% glass fiber reinforced, heat stabilized polyamide 66 resin was developed for good retention of properties over time at temperatures up to 220 degrees C.

OEM/Vehicle Hyundai Motor Company 2018 Genesis G80, Kia Stinger System Supplier Hwaseung R&A Co., Ltd. Material Processor    Songwoo Industrial Seji Solotech, Inc.

Material Supplier DuPont Korea Inc. Resin PA66

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

Brake Light Lenses

Coating elimination, through the use of a standard colored polycarbonate (PC) with specialty copolymers, enabled a cost reduction of $0.80 per part and a program cost avoidance of $145,000 annually. The lenses are weatherable and directly recyclable. Coating elimination avoids VOC emissions and water use (cleaning the paint line) resulting in further environmental benefits.

OEM/Vehicle General Motors 2018 Chevrolet Onix System Supplier Olsa Material Processor    Olsa

Material Supplier SABIC Resin Lexan SLX 2271T PC Tooling/Equipment Supplier Olsa

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

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

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

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

Ultra Capacitor Barrier Shield

This application uses material recycled from tires and plastic caps to make TPE shields to protect the ultra capacitor from the hotter surrounding environment by deflecting heat away from it. This has prevented 5,000 tires and 25,000 lbs of plastics from landfills to date. Die cutting, thermoforming and vibration welding is used to produce this part for the first time, opposed to 2-shot injection molding, resulting in an $80,000 savings in tooling compared to tooling for steel or aluminum used previously. A 16 week same save is also achieved. Consumers benefit as the heat shields keep the battery cool preventing possible battery failure. This application can be translated to other exterior applications.

OEM/Vehicle General Motors 2018 Cadillac CTS System Supplier GDC Incorporated Material Processor    GDC Incorporated

Resin Enduraprene 2390/2195Re TPO Tooling/Equipment Supplier GDC Incorporated

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

Use of Soybean Oil in Slap Pad

This is the first use of soybean oil, to replace up to 40% of the 100% petroleum oil in the natural rubber part. It can be translated to any vehicle line with leaf springs including trucks, vans and SUVs. The current volume of petroleum oil being replaced in this application is approximately 522 gallons/year. This replacement of petroleum oil, with a natural resource, also offers a reduction in noise and an improvement in part durability. This will result in a reduction in warranty replacement of slap pads, estimated as a $2.5M warranty cost avoidance.

OEM/Vehicle Ford Motor Company 2018 Ford F150 System Supplier Rassini Material Processor    Rassini

For More Information See: http://www.plastics-car.com/Recycling/Life-Cycle-Assessment-Public-Policy-Development