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

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

Precise Integration Enabled System

The precision integration-enabled system is a patented locating and attachment feature that minimizes gaps or movement as well as manufacturing variation common with snap fits while leveraging the inherent elastic deformation properties of plastic.  No external fixtures are needed, labor is reduced, and ergonomics are improved. This is the first application to use a MIC bezel for the housing that prevented water migration without need for additional seals. Also, the typical tooling action needed to mold snap fits was eliminated, saving tooling time and costs.

OEM/Vehicle General Motors Co. 2015 Chevrolet Volt System Supplier ITW Deltar Material Processor    ITW Deltar

Material Supplier Celanese Corp. Resin MetaLX Hostaform POM Tooling/Equipment Supplier ITW Deltar

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

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

Dual Snap Hardware Mechanism

This is the first rear-door, window-lift carrier-plate mechanism that is all-plastic and features a double (dual) snap. It delivers design flexibility, labor cost savings, and greater design efficiency with multiple glass constructions, meeting project goals to reduce processing and assembly time, maintain rotational stability, and reduce design complexity. An injection molded, 2-shot, TPC-ET overmolded POM design integrates both a down-stop bumper and a glass bumper, eliminating a component and assembly steps. The innovative design also includes an additional snap-feature attachment to support glass tracking during up/down operations.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Hi-Lex Corp. Material Processor    Hi-Lex Corp.

Material Supplier Celanese Corp. Resin Celcon POM / Riteflex M25 TPE Tooling/Equipment Supplier MPP

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

Unidirectional Inertial Lockout

This console bin door has no latch in the closed position, but a undirectional inertial lockout feature was implemented to meet FMVSS 201. The lockout's inertial sensitivity is defined by part geometry, allowing it to be made of any material while maintaining the same inertial properties. A single injection-molded snap-in lever plus felt tape replaced multiple die-cast metal components, minimizing testing costs due to compliance the first time, increasing reliability, and saving 7.85 g and $0.84 USD costs vs. the previous metal option.

OEM/Vehicle Ford Motor Co. 2016 Lincoln MKC System Supplier International Automotive Components Group Material Processor West Michigan Molding, Inc.

Material Supplier Celanese Resin Celcon LW90-S2 POM

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

Charge-Port Bezel

Thanks to use of elastic averaging, this injection-molded charge-port bezel is located very precisely with no gaps or movement normally associated with typical cantilevered snap-fit components. The application also used molded-in-color POM material, which provided the appearance of chrome without the cost or environmental concerns. The design also helped reduce labor to install and ensure the part was centered in the charge-port opening.

OEM/Vehicle General Motors Co. 2016 Chevrolet Volt System Supplier ITW Deltar Material Processor ITW Deltar

Material Supplier Celanese Resin MetaLX Hostaform POM Tooling/Equipment Supplier ITW Deltar

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

Split-Link Safety Device

This injection-molded POM-link mechanism is designed to perform 3 functions, depending on the state of the vehicle.  It provides latch lock/unlock position, impatient -passenger feature, yet folds under inertial load and protects passenger during a crash by disconnecting the release portion of the latch so the door will not pop open. Implementing this part required no changes to the door panel or handle counterweights. It was easy to prototype and produce the plastic part, which can be molded into shapes steel cannot.  This application demonstrates that plastic components can be used to solve high-impact energy problems.

OEM/Vehicle Ford Motor Co. 2015 Ford Transit van System Supplier Magna Closures

Material Supplier DuPont Automotive Resin Delrin 100P POM

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

MIC Metallic Console Rail

This currently is the first MIC metallic-look console component as well as the longest MIC/metallic part in the industry. It increases interior harmony by having the same material on door trim and console rail vs. painted parts, which look different when placed side-by-side. Durability is increased because the color will not chip or wear off, which reduces warranty claims, assembly scrap, and costs.  It also provides a better surface appearance and a silky feel while reducing cost 40% per vehicle.

OEM/Vehicle Ford Motor Co. 2014 Ford Edge CUV System Supplier Johnson Controls Inc. Material Processor DT Manufacturing Co.

Material Supplier Celanese Resin Hostaform LX90Z XAP2 POM Tooling/Equipment Supplier Excel Global

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

Fuel Filler Neck

This part combines the advantages of an injection-moldable thermoplastic (excellent design freedom and 30% lower weight vs. metal) with the proven fuel resistance of POM and consistent electrical conductivity per SAEJ1645.  The material can be used with the full range of liquid fuels, including diesel and aggressive high-alcohol fuels. Despite the material's inherent conductivity, the part is easy to process and provides extra safety during filling of the fuel tank.

OEM/Vehicle Volkswagen AG 2013 Golf A7 hatchback System Supplier TI Automotive Material Processor Microtechnic

Material Supplier Celanese Resin Hostaform EC140XF POM

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Fuel-Systems?css=print

Headrest Guide Sleeve

A new grade of impact-modified, UV-stable, color-matched POM copolymer was developed to manage EU impact safety requirements for seating and headrests.  Without requiring any tooling changes, the new material corrects failures in non-impact-modified POM headrest sleeves while reducing weight 2% and providing greater safety in rear-impact collisions.

OEM/Vehicle Ford Motor Co. 2015 Ford Fusion mid-size car System Supplier Lear Corp. Material Processor ITW Deltar

Material Supplier Celanese Resin Hostaform SXT90Z-01 POM

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

Plastic Fuel-Pump Maintenance Lid

This is the first 1-piece plastic fuel-pump maintenance lid with molded-in fasteners that is serviceable and can withstand challenging impact force. Significant FEA work was done to ensure the design would meet impact requirements. Additionally, the part seals out noise and fumes, reduces mass and cost, and helps prevent line-worker injuries during installation vs. the stamped metal lids it replaced.

OEM/Vehicle Honda Motor Co. Ltd. 2014 Acura TL luxury sedan System Supplier Nifco America Corp.

Material Supplier Celanese Resin Hostaform S9364 POM

For More Information See: http://www.plastics-car.com/s_plasticscar/fuel_economy/Default.html