D Optic LED Headlamp

This innovative headlamp system features scalable modular design flexibility. The customer can add elements to achieve styling and/or performance objectives. The lenses are single shot thick molded elements, with extremely tight tolerance and high optical clarity requirements. They simplify conventional optical systems in which multiple components (reflector, shield and lens) must be positioned very precisely, with a system of pairing a precisely molded lens with a single 1 x 1 LED light source. A high temperature grade acrylic material enables the modular lenses to be placed very close to the light source, within 300 - 500 micros, to maximize the amount of light captured form the LED. The Traverse headlamp has three vertically large integrated lenses alongside six individual compact lenses.

OEM/Vehicle General Motors 2018 Chevrolet Traverse System Supplier Magna Autosystems

Material Supplier Arkema Resin Plexiglas HT-121 PMMA

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

Headlamp Light Curtain

The lamp appears crystal clear when unlit but has a glowing appearance when lit. The light scattering properties of the new material convert the light guide to a fully illuminated panel, that can be used with any color LED, opening a new degree of freedom for designers. Previously, clear PMMA without this light

scattering additive was used, and structures on the surface of the light pipe, along with multiple LEDs behind the part, had to be used. These traditional light guides and light pipes resulted in bright spots and a milky (grained)unlit appearance. The new headlamps give the consumer premium headlamp styling due to a homogeneously lit light function. Safety is enhanced as there is better visibility due to a larger illuminated surface easier to detect with the human eye. A 3D effect can also be achieved.

OEM/Vehicle General Motors 2016 Cadillac CT6 System Supplier Hella KGaA Hueck & Co

Material Supplier Evonik Cyro LLC Resin Acrylite LD96 PMMA

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

Illuminated Emblem

Combination of a 2-shot overmolded lens and 2-shot light guide utilizing multiple materials, and laser welding in one package enabled efficient production of this backlit chrome emblem. Twoshot molding the lens eliminated the need for excess material and energy associated with conventional hardcoating processes. A twoshot light guide was developed with selective areas of transparent and diffusion material into a single sub-component. This solved significant technical difficulties to achieve even lighting across a large surface area within a tight packaging space.


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

OEM/Vehicle General Motors 2017 Chevrolet Camaro, Silverado, Colorado System Supplier Windsor Mold Group Material Processor  Emrick Plastics

Material Supplier SABIC, Arkema Resin Lexan LS1 & Lexan SLX2271T PC Plexiglas V825 PMMA Tooling/Equipment Supplier Windsor Mold Group

Illuminated Beverage-Holder Assembly

This patented and package-friendly application takes advantage of the optical transparency of PMMA and geometrically mirrored surfaces to move light in an innovative and efficient manner upward from the bottom of the cupholder via a single cup-plate component. By eliminating a 2-shot illuminated ring sitting on the side of the cupholder, glare is avoided, scrap-rate is reduced, and there is no need for a special press and tooling, helping reduce costs.

OEM/Vehicle Ford Motor Co. 2015 Lincoln MKC & MKX System Supplier Pacific Insight Electronics Corp. Material Processor Blue Star Inc.

Resin PMMA Tooling/Equipment Supplier Blue Star Inc.

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

2-Shot Injection-Molded Cluster Bezel

In this application, a 2-shot component produced on a rotary injection-molding press replaces a standard clear lens + painted bezel.  This allows removal of an assembly joint, creates a unique cut-out in the instrument panel over the instrument cluster, and produces an A-surface with molded piano-black finish, eliminating post-mold painting. The result is increased craftsmanship and design quality by eliminating a sealing defect. Thanks to formation of a chemical bond between PMMA and PC-ITR materials, eliminating variance due to welding, spacing is consistent.

OEM/Vehicle General Motors Co. 2016 Chevrolet Camaro System Supplier Visteon Corp. Material Processor Windsor Mold Group

Material Supplier SABIC Resin LEXAN SLX1432 PC-ITR, PMMA Tooling/Equipment Supplier Windsor Mold Group

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

Blind Spot Information System (BLIS) Tail Lamp

This blind-spot information system (BLIS) sensor has uniquely been integrated into the rear tail-lamp assembly because the vehicle's aluminum bumper does not permit normal installation behind the plastic fascia. The radar unit is housed behind 2 layers of plastic on a 3-color, 3-shot tail-lamp lens and features a cast-aluminum serviceable door, which also acts as a heat sink.  By installing the BLIS system in the tail lamp, the lens cover also protects the module from direct impact, water, mud, or snow and the system saves $10 USD/vehicle plus a $15-million USD cost avoidance.

OEM/Vehicle Ford Motor Co. 2015 Ford F-150 pickup System Supplier Flex-N-Gate Corp. Material Processor Flex-N-Gate Corp.

Material Supplier Arkema Group Resin V826 Acrylic PMMA Tooling/Equipment Supplier Ventra Sandusky, LLC

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

Illuminated Grille Badge

During daylight, this unique grille badge displays a 3D chromed look, but in low light it is illuminated -- an industry-first for exterior ornamentation. Injection-molded PMMA with crushed glass particles (for a sparkly look) and the unique TECHNO (translucent, electro-chromatic, high-intensity novelty optics) process for applying an electro-chromatic layer and sealed low-voltage wiring/LED assembly replaces the hazardous, time consuming, and costly chrome plating process while creating a unique effect that will not flake, peel or delaminate over time.  The part is serviceable without removing the grille and can be installed on current or previous models.

OEM/Vehicle Ford Motor Co. 2013MY Ford Mustang System Supplier Colonial Plastics, Inc. Material Processor Colonial Plastics, Inc.

Material Supplier Entec Resin PMMA Tooling/Equipment Supplier Colonial Mold, Inc.

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

Bright Film Outer Belts

The change from stainless steel to PMMA with a bright foil cap for the outer belt wrap lowered cost 47%/vehicle (by eliminating end caps and stretch bending); reduced mass 18%/vehicle; improved customer fit & finish by using a material with low CLTE for tighter margins; eliminated corrosion and sharp corners; improved serviceability; and increased design flexibility by creating a smooth transition between fixed glass and belts.

OEM/Vehicle Ford Motor Co. 2012MY B-Max System Supplier Cooper Standard Material Processor Cooper Standard

Material Supplier 3M Co. Resin 3M Alum Foil 3340 Blended tri-layer PMMA Tooling/Equipment Supplier Kunstoff GmbH

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

Molded-In-Color Ornamentation

This new flush-fit, MIC badge delivers improved functional performance vs. the current screen-printed aluminum part while eliminating paint and improving quality.  The PMMA material provides excellent gloss and color retention even after 3,000 hr with robust impact and scratch-resistance properties while also creating a 3-D look with improved readability. Heat-staking of front lens to ring and chrome base reduces BSR.

OEM/Vehicle Ford Motor Co. 2013MY Ford Fusion System Supplier Tribar Manufacturing LLC Material Processor Tribar Manufacturing LLC

Material Supplier Arkema  Inc. Resin Plexiglas MI-7 46076 PMMA Tooling/Equipment Supplier Granby Mold, Inc.

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

Acrylic Appliqués w/SecureCode™ Invisible Keypad

The high-gloss black acrylic pillar appliqués features Ford's industry-first SecureCode™ invisible-touchpad keyless-entry system while facilitating the Flex CUV's signature floating roof design.  First-surface dual-shot molding technology, highly polished precision tools, along with uniquely tuned acrylic materials are used to provide a mirror-like finish, and excellent dent, ding, and scratch resistance that is superior to metal appliqués.

OEM/Vehicle 2009MY Ford Motor Co. Ford® Flex™ CUV System Supplier Windsor Mold Material Processor Windsor Mold

Material Supplier Arkema Resin Plexiglass® PMMA Tooling/Equipment Supplier Windsor Mold

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

Rear Combination Lamp with LED Sequential-Turn Signal

Rear lighting on the 2010 Mustang sports car is a modern, all-plastic execution of the classic Ford designs of the ‘60s, coupled with the reliability of LED lighting and the benefits of lightweight, break-resistant all-plastic lamps. The fully serviceable lamps feature high-definition graphics optimized through the use of computer simulation, use of optical-grade acrylic, and precision-molding technology, delivering a design that harkens back to the ‘67MY Cougar® sedan and ‘68MY Shelby® Mustang® sports car.

OEM/Vehicle 2010MY Ford Motor Co.: Ford® Mustang® Sports Car System Supplier Valeo-Sylvania Material Processor Valeo-Sylvania

Resin   PMMA Tooling/Equipment Supplier Active-Burgess

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

Dual-Lens Cupholder Light

In this next-generation interior-lighting application, a 1-piece design integrates primary illumination surface and show-surface lens for improved craftsmanship, 10% weight savings, and $0.35 USD cost savings vs. previous 2-piece lens designs.  The design also reduced assembly costs and lowered warranty issues.

OEM/Vehicle Ford Motor Co. 2011 Ford Explorer System Supplier Chicago Miniature Lighting, LLC Material Processor Chicago Miniature Lighting, LLC

Material Supplier Ashland Resin Cyro Acrylite 8N-123-000 PMMA Tooling/Equipment Supplier Global Management & Sales Group

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

B-Pillar Appliqué

This is a dual-shot (ABS over PMMA), injection-molded decorative pillar appliqué  provides excellent aesthetics  and electrical functionality for the vehicle’s keyless entry system.  It also provides glass guidance, replacing a steel u-channel.  Filling analysis was critical to the success of this design to prevent cracking and over-stressed parts in joints and corners.  The result is a 46% weight savings, a $1.4MM USD direct cost savings, and an additional $800,000 USD indirect cost savings.

OEM/Vehicle Ford Motor Co. 2011 Ford Focus compact car System Supplier Windsor Mold Group Material Processor Windsor Mold Group

Material Supplier Evonik Industries Resins Acrylite ABS, PMMA Tooling/Equipment Supplier Windsor Mold Group

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Chassis-Design-NVH-Performance/Support.html