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

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

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

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

Lightweight TPO Bumper Cover

A new, lighter weight TPO bumper cover was developed using high-crystallinity PP, ethylene-octane rubber, and a combination of nano-size talc and micron-size whisker fillers similar to magnesium oxysulfate.  The material provides high mechanical performance, improved dimensional stability, and low CLTE thanks to the high aspect ratio filler. Weight is reduced 7-10% and the material is cost neutral vs. the material it replaced. Additionally, 6 patents have been obtained on the development.

OEM/Vehicle Hyundai Motor Group 2017 Hyundai Genesis G90 System Supplier ECO Plastic Material Processor    ECO Plastic

Material Supplier Hanwha Total Petrochemicals Co., Ltd. Resin NB71 TPO Tooling/Equipment Supplier Hyundai Motor Company

For More Information See: http://www.plastics-car.com/FAQs/Plastics-Processing.html?css=print

Vacuum Brake Tubes

A high-performance thermoplastic was needed for vacuum brake tubing to replace reinforced rubber. It needed broad temperature performance (-40-150C), chemical resistance, burst strength to 60 bar min. and flexural strength to 50 N min. It also had to resist vacuum collapse after 2 hr @ 150C and provide impact retention after 336 hr @ 150C. The design was changed to use a smaller diameter, thinner wall to simplify engine/undercarriage routing and eliminate heat shields plus allow quick connects. A TPC-ET elastomer with high thermal oxidative stability was developed. It is 30% lighter, less costly, and eliminates brackets.

OEM/Vehicle General Motors Co. 2016 Chevrolet Silverado & GMC Sierra System Supplier Cooper Standard Material Processor    Cooper Standard

Material Supplier DSM Engineering Plastics Resin Arnitel CM622 TPE

For More Information See: http://www.plastics-car.com/FAQs/Careers-in-Plastics.html?css=print

Rhapsody Blue MIC Vehicle Environment

Project goals were to achieve a unique MIC color space that looks luxurious but appeals to today's generation. It involved using the first transparent pigment-based interior color deliverable across 76 base resins for the vehicle interior. Once the color was mastered, early attempts showed it was prone to metamerism with a red/green directional hue shift. Numerous attempts to achieve color consistency bidirectionally with standard pigment adjustments did not solve the problem. Finally, the color was remastered using a non-TIO2 system that did not exhibit hue shift, eliminating the need to paint and creating a calming, cool color environment.

OEM/Vehicle Ford Motor Co. 2016 Lincoln Continental System Supplier Americhem Inc. Material Processor    Many

Material Supplier Americhem Inc. Resin PP,TPO, ABS,PA, POM Tooling/Equipment Supplier Many

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

Transmission Oil Catcher

This transmission oil catcher returns transmission oil efficiently to the planetary gear bearings. Since the carrier spins at 7,500 RPMs, is exposed to hot automatic transmission fluid, and has clearances of 0.25 mm, the part cannot warp or creep and must provide excellent chemical resistance. A 50% LF-PPA grade with a complex runner system is used to mold parts with 1.2 mm walls (40% thinner than previous PA grades). The new product improves transmission reliability and lifespan, reduces NVH from gear noise, accommodates tight packaging space, and reduces mass 65% vs. metal designs.

OEM/Vehicle Ford Motor Co. 2017 Ford F-150 System Supplier Parker Hannifin Corp Material Processor    Chomerics Div. of Parker Hannifin Corp.

Material Supplier DuPont Automotive Resin Zytel® HTN51LG50HSL BK083 PPA Tooling/Equipment Supplier Chomerics Div. of Parker Hannifin Corp.

For More Information See: http://www.plastics-car.com/FAQs/Safety.html?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

New PC/ABS for Exterior Applications

Development of new filler technology with very-low CLTE improved dimensional stability and reduced gap sizes for exterior PC/ABS parts, helping improve fit & finish. High gloss and enhanced paint adhesion makes the material an excellent choice for painted applications. The new grade also is lower density (10%) for lighter lower-cost parts, provides excellent impact strength for better durability, and has improved dimensional stability to reduce warpage. And because MFI is increased, parts can be molded faster and in thinner walls. This allowed the new material to replace aluminum at half the weight and 40% cost reduction (excluding tooling).

OEM/Vehicle General Motors Co. 2016 Opel Astra Sports Tourer System Supplier General Motors Europe Material Processor    SRG Global

Material Supplier Trinseo LLC Resin PULSE XT9215 PC/ABS Tooling/Equipment Supplier Socem / SRG Global

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

EV Home Charging Station

To meet demanding performance requirements for EV home charging unit base plates, a special flame-retardant PC/siloxane compound was developed. The material contains no halogenated additives, offers excellent low-temperature toughness and weatherability, plus improved chemical resistance. Additionally, the PC/Si material provides superior moldability for parts with deep cavities and low draft angles, and crack resistance at pinch points, which makes it easier to attach the plate with screws to home or garage.

OEM/Vehicle Daimler AG 2016 Daimler EV Fleet System Supplier ABL Sursum Material Processor    ABL Sursum

Material Supplier Trinseo LLC Resin EMERGE PC/Si XZ92705.00 PC

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