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

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

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

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

Post Consumer Recycled PA66 for Window Support Bracket

For this application, 100% PCR (Post Consumer Recycled) PA66 resin replaced virgin PA66 and PP resins to provide high damping properties to reduce or eliminate squeak, rattle and window vibration. As damping properties are inherent in PA 66 resin, no new product development was required. As the same injection

molding process used to process the former resins as the new recycled material could be used, no new tooling was required either. This process can be translated to other applications further reducing landfill waste.

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

Material Supplier Ravago Resin Enviramid N1335HL, 30167 35% GFR, PCR, PA66

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

Seat Armrests in Recycled Nylon

Part performance was improved and manufacturing costs were reduced using 100% recycled nylon 66 (33% glass-filled) with strength properties exceeding the original 40% long-glass filled polypropylene material's performance. The recycled nylon was formulated to utilize identical shrink values as the polypropylene (original substrate material) avoiding tooling cost and timing impacts. A cost avoidance of $0.35 per armrest was realized by utilizing recycled glass filled nylon instead of virgin glass filled nylon. A significant safety benefit is also achieved as the recycled material provides the armrest with a 60% increase in breaking strength above FCA specifications.

OEM/Vehicle FCA US LLC 2016 Chrysler Pacifica System Supplier Williamston Products Inc. Material Processor    AGS Technology Inc.

Material Supplier AGS Technology Inc. Resin Injectoblend FPA66235-2RU PA66 33FG Recycled Tooling/Equipment Supplier Aalbers Tool and Mold

For More Information See: http://www.plastics-car.com/Recycling/Recycling-of-End-of-Life-Vehicles_1

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

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

Modular Composite Front-Seat Cushion Pan

This patent-pending, plastics-intensive, modular composite front seat-cushion pan (in impact-modified 35% GR-PA), side-airbag deployment back panel (in talc-filled TPO), and power head-restraint drive nut (in POM) create a robust and dynamic crash-energy management system for front impact protection, side airbag deployment, and energy management for occupant impact protection. Further, the system enables modular assembly and scalable features for assembly ease.  Already 83 patents have been filed and 12 granted on this innovative seat system. 

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Leggett & Platt / Great Lakes Trim / Grammer Industries Material Processor    MacLean-Fogg / Grand Traverse Plastics / Johnson Electric

Material Supplier BASF Corp. / Advanced Composites, Inc. / DuPont Automotive Resin Many Tooling/Equipment Supplier MacLean-Fogg / Grand Traverse Plastics / Johnson Electric

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

Hot Gas Welded Thermostat Housing Assembly

Hot-gas welding joins both halves of this 35% GR-PPA thermostat housing assembly. The part has a small welding-flange footprint but high weld strength because there is no fiber/material degradation during the joining process. In fact, it is the only welding process that permits bridging of glass across the joint. The weld distance is held within 0.1 mm, enabling parts to package into very limited spaces with tight tolerances. Since the part is not touched during welding, there is no sticking. Versus previous aluminum solutions, the PPA assembly is 30% lighter and 40% less costly.

OEM/Vehicle Ford Motor Co. 2017 3.5L V6 Cyclone TiVCT GTDI engines System Supplier Plastic Tec - Bocar Group Material Processor    Plastic Tec - Bocar Group

Material Supplier DuPont Automotive Resin Zytel HTN51G35HSLR BK420 PA Tooling/Equipment Supplier Schweiger GmbH & Co. KG

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

Composite Tambour Door

This application features an insert-molded wood composite that is back injected via 15 gates to create individual plastic slats that are connected in the back. A 3-axis laser is used to separate wood between slats for a cohesive grain appearance. Unlike conventional flat compression molded wood tambour doors featuring layers of veneer, interply, and adhesive, these doors are curved. The part features 63% GR-PA 6/6 with extremely low shrink (0.05 mm) to match the non-shrinking wood. Use of a large number of gates on a relatively small part eliminates warpage.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier NBHX Trim GmbH Material Processor    American Autocoat

Material Supplier BASF Corp. Resin Ultramid B3WG13 BK00102 PA66 - 63%GF Tooling/Equipment Supplier Classic Die Precision Plastic Molds

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Interior/Auto-Upholstery.html

2.0L GTDI Turbo Compressor Outlet Duct

To meet more stringent fuel efficiency and tailpipe emissions requirements, engines increasingly are being downsized and turbocharged, but that raises temperatures and pressures that underhood components see during operation. For example, charge air ducts, which take air from the turbocharger to the throttle body, can see continuous-use temps as high as 220C and pressures as high as 207 KPa. Further, compact packaging space requires efficient designs. Switching to a heat-stabilized PA 6/6 capable of being 3D flashless blow molded reduced mass 30-40% and cost 20-25% vs. metallic designs.

OEM/Vehicle FCA 2017 Alpha Romeo Grigorio System Supplier ABC Group, Inc. Material Processor    ABC Group, Inc.

Material Supplier BASF Corp. Resin Ultramid Endure D5G3 BM PA Tooling/Equipment Supplier ABC Group, Inc.

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

Transmission Bottom Pan

An injection molded 50% long-glass PA 6/6 serves as the main bottom oil pan for a 10-speed automatic transmission. It not only must provide chemical resistance to hot automatic transmission fluid, and maintain structural and sealing integrity for the life of the vehicle without deflection due to extremely tight stack up, but it also must resist damage from road debris and nearby exhaust plumbing. Furthermore, the pan is required to support the full weight of the transmission when the latter is removed from the vehicle. It reduces weight 55% and cost 15% vs. previous steel pans.

OEM/Vehicle Ford Motor Co. 2017 Ford F-150 System Supplier Sogefi Group Material Processor    Sogefi Group

Material Supplier DuPont Automotive Resin Zytel 75LG50HSL BK031 PA66 Tooling/Equipment Supplier Sogefi Group

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