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

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

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

Rear Quarter Window

Global industry's largest-ever (1200 x 450 mm) 2-component polycarbonate rear quarter window(RQW) on a production vehicle is 40% lighter (3kg lighter) and substantially more impact resistant vs. comparable RQW in glass. It also features design elements that cannot be achieved with glass, contributing to the more innovative exterior of the new-generation GL8.

OEM/Vehicle SAIC General Motors (SGM) 2017 Buick GL8 System Supplier Shentong Material Processor    Shentong

Material Supplier SABIC Resin Lexan GLX143 PC Cycoloy XCM830 PC/ABS Tooling/Equipment Supplier Inglass

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

Functional Spoiler Stanchion

Thermoplastic (ABS+PC) replaced metal to injection mold this spoiler stanchion enabling stylish, aerodynamics and an 86% weight savings while meeting strength/stiffness requirements. An innovative attachment scheme, including long bolts and compression limiters designed to attach the stanchions to the spoiler and to the vehicle without exposing the fasteners, was designed. Unique core out slides in the tool were created to enable the hollow stanchion design.

OEM/Vehicle General Motors 2018 Chevrolet Camaro ZL1 1LE System Supplier Transglobal Material Processor    Proper Tooling

Material Supplier Trinseo Resin Pulse 2000EZ PC/ABS Tooling/Equipment Supplier Proper Tooling

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

First Polycarbonate Instrument Panel

The first use of polycarbonate (PC) to injection mold a hard (painted) instrument panel (IP) featured on the 1977 Econoline van is the 2016 Hall of Fame winner. PC and PC blends have been used to mold IP retainers, uppers, upper trim, lowers, and lower trim for both hard (painted) and soft (skin & foam) IP systems for the last 39 years. The application proliferated from commercial vans to pickups, passenger cars, and SUVs. To date an estimated 200-million IPs using 2-billion pounds/907,185 tonnes of PC or PC blends have been produced globally in the passenger vehicle market.

OEM/Vehicle Ford Motor Co. 1977 Econoline® Van System Supplier Ford Saline / Faurecia Interior Systems Material Processor    Ford Saline / Faurecia Interior Systems

Material Supplier GE Plastics / SABIC Resin Lexan PC

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

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

Outer Handle

This application is industry's first belt-integrated, outside door handle with switch activation to open both front and rear doors. The slender, minimalist, all-plastic, high-luster chrome-finish handle provides effortless operation, luxury feel, and quiet operation. The injection molded PC/ABS part with integrated zinc casting also features an e-handle with power-release switch to deliver a sleek, uninterrupted form that reduces mass 20% and cost 35% vs. conventional bond-on-bracket designs.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier ADAC Automotive Material Processor    ADAC Automotive

Material Supplier SABIC Resin Cycoloy C1200HF PC/ABS Tooling/Equipment Supplier Xinpoint

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

Quad-Barrel Convertible Cupholder

This console design converts from 2 cupholders plus a bin to 4 cupholders with the help of a patented slider tray assembly for greater user flexibility without the need to remove and stow components when not in use. The design of the injection molded PC/ABS cupholders accommodates beverage containers ranging from small coffee cups and water bottles to large all-day beverage containers while reducing weight 70% vs. the outgoing model and lowering costs $3 USD depending on content replaced.

OEM/Vehicle Ford Motor Co. 2017 Ford Super Duty System Supplier Summit Polymers, Inc. Material Processor    Summit Polymers, Inc.

Material Supplier SABIC Resin Cycolac XCY620 PC/ABS

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

3D Radiator Grille

A new appearance is achieved for this front grille by using "varied contouring" (variable wall thicknesses) on the B side of this injection molded, tinted PC part, which subsequently is UV coated on the A side and receives a 3-coat paint system on the B side. The end result is a unique 3D look on a 2D surface.

OEM/Vehicle General Motors Co. 2017 Chevrolet Bolt System Supplier Sam Shin Chemical Co. Material Processor    Sam Shin Chemical Co.

Material Supplier LG Chem Ltd. Resin LUPOY 1000MU PC Tooling/Equipment Supplier A-Tech Solution Co., Ltd

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

Rear Lamp Reflector

Rear lighting plays an important safety and branding role. New lighting technologies have been combined with plastics to create innovative new designs, such as this rear lamp with unique lit and unlit appearance. The system uses high specular and diffuse reflection from multiple LEDs to create a homogeneous light glow. Thanks to a special color additive, the white polymer's high reflectivity after molding and heat aging, and minimal color shift eliminates the need for direct metallization or painting. Injection molding also enables design features like clips to be integrally molded close to LED circuit boards.

OEM/Vehicle FCA US LLC 2015 Dodge Challenger System Supplier Varroc Lighting Systems Material Processor Varroc Lighting Systems

Material Supplier SABIC Resin LEXAN™ LUX 2289 PC

For More Information See: 

Front Door Polycarbonate Windows

This application is the first, fully homologated, lightweight, race-like front door with sliding window in polycarbonate glazing and protective plasma surface treatment that met all performance and homologation requirements. The door's polycarbonate glazing also features a sliding rail and small moving plastic glazing with water management. Although the solution is not feasible in conventional glass, the current design is approximately 40% lighter than glass would have been. The application is a good example of using plastics to excite and better appeal to customer while enabling regulatory compliance, homologation, and mass reduction for better performance.

OEM/Vehicle FCA Italy S.p.A. 2015 Abarth 695 Biposto System Supplier ISOCLIMA Material Processor Exactec LLC

Material Supplier SABIC Resin LEXAN PC with EXATEC coating 9030HO-GN9018T

For More Information See: http://www.plastics-car.com/Automotive-Center/Member-Companies?css=print

Lightweight Wind Deflector

This is the first use of a self-mounted, transparent and frameless wind deflector for convertible cars that meets AS2 ANSI and ECE requirements. The steeply raked design minimizes air turbulence and noise when the top is down. Replacing glass with PC lowered mass 33% and allowed a contoured shape to be achieved that would have been difficult and costly in glass. A laser-etched monogram under the surface is unobtrusive to vision during driving, yet visible during inspection and meets regulatory requirements for glass marking. A plasma coating enhances scratch, chemical, and UV resistance for long use life.

OEM/Vehicle General Motors Co. 2016 Corvette Stingray Convertible System Supplier Polytec FOHA Inc. Material Processor SABIC

Material Supplier SABIC Resin LEXAN 9043 PC w/Exatec 900 coating Tooling/Equipment Supplier Pace Machine Tool, Inc.

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