Volt Battery Impact Shield

This low cost, simple crash barrier protection shield boasts rapid development and implementation with innovative materials and molding. Six parts were molded together as one mold, requiring calculating the materials reaction when secondary waterjet cuts out each piece. Three composite material constructions were tested (polypropylene with 40%, 50% then 60% glass) while tooling and 12 sets of prototype parts were developed over a 6 week period. A test vehicle was crashed, with production intent parts, passing all

test criteria the following week. Production tooling and fixtures were also completed during that time (week 7). Full production was initiated in week 12. A 75% mass and 60% cost saving vs traditional high strength steel stamping with metal fabrication was achieved.

OEM/Vehicle General Motors 2017 Buick Enclave System Supplier CSP Teijin Material Processor    CSP Teijin

Material Supplier Quadrant Plastic Composites Resin GMTex X103F61-4/1-0/90° PP Tooling/Equipment Supplier Laval Tool and Mould

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Electrical-System/Connectors.html?css=print

Energy Absorbing Collapsible Glove Box Bin

This bin, that holds and stores the owner's manual, collapses during impact to prevent severe femur loads while providing a beautiful flocked appearance. The new design provides a 400 gram weight savings while lowering femur loads from unacceptable to 5-star compliant. The support structure is injection molded with a
compressed PET internal shell. This 100% recyclable, patent pending, concept can be used on any vehicle line to address high femur load issues and assist in achieving a 5-star crash rating.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition System Supplier Detroit Manufacturing Systems Material Processor    Detroit Manufacturing Systems

Material Supplier Advanced Composites Resin Basell - SG702 PP Tooling/Equipment Supplier Lamko Tool & Mold

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Car-Electrical-System/Switches-Sockets.html?css=print

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

Door Edge Protector

This industry first door guard system protects all doors from dings and scratches - and neighboring vehicles as well. The door guard is not visible until it articulates out upon opening of the door. Parts are injection molded and no metal fasteners are needed. This is a marketing feature add on of $100/vehicle offering an estimated $500K warranty savings per year.

OEM/Vehicle Ford Motor Company 2017 Ford Fiesta System Supplier Witte Automotive Material Processor    Witte Automotive

Material Supplier Washington Penn Resin H2TF-2B PP Tooling/Equipment Supplier Witte Automotive

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

Rear Seat Entertainment System

This Rear Seat Entertainment System was repositioned from the back of the front seat headrest to the upper seat back/lower portion of the head rest area for improved viewing comfort and ergonomics. No change in the existing seat structure was required with this common design for both the driver and passenger seat. The DVD system was removed to enable a larger screen and this resulted in a 30% cost reduction.

OEM/Vehicle Ford Motor Company 2018 Lincoln Navigator System Supplier Magna Material Processor    Great Lakes Trim

Material Supplier Advanced Composites Resin ADX 5028 PP Tooling/Equipment Supplier Great Lakes Trim

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

Storage Box Interlocking Down Stop

An interlock is integrated into the traditional GB down stop design to make the TPO down stop super strong and still achieve very low disengagement effort for service and assembling. For the traditional design, low disengagement effort for service or assembling and robust down stop for customer abuse conflict with each other. Making one better will worsen the other. The interlocking down stop design decouples the two and allows for engineers to lower the disengagement effort and strengthen the down stop as needed. This results in a cost savings of $.90 per vehicle ($.50 piece price savings and $.40 labor savings) compared with removable down stops.

OEM/Vehicle Ford Motor Company 2018 Lincoln Navigator System Supplier DMS Material Processor    DMS

Material Supplier Advanced Composites Resin ATX 832N PP Tooling/Equipment Supplier Lamko Tool & Mould Inc.

For More Information See: http://www.plastics-car.com/Partners/Trade-Associations

Cargo Protector

This cargo protector eliminates a major design flaw on large SUVs by blocking the dynamic progress of rolling containers such as grocery items or objects such as small sports items while preventing them from falling out of the vehicle when the liftgate is opened. It also prevents items from "perching" on the scuff when the liftgate is closed, and avoiding item roll-out when the liftgate is opened by limiting the upper flat surface of the scuff and how it interfaces with the liftgate trim. The scuff's beveled surface allows much easier removal of cargo items than a square-edged surface which is fairly common on small and mid-sized SUVs and CUVs.

OEM/Vehicle Ford Motor Company 2018 Ford Explorer, Lincoln Navigator System Supplier Beach Mold Material Processor    Beach Mold

Material Supplier ExxonMobil Resin 7885 PP Tooling/Equipment Supplier ToolPlas Systems, Inc.

For More Information See: http://www.plastics-car.com/Partners/Professional-Associations

Instrument Panel Carrier

Long glass fiber PP injection molding via structural chemical foaming with core-back process enabled the production of this part with very low VOC emissions, meeting VDA 278 specification. Extensive CAE work predicting warpage of the foamed part provided valuable insights, allowing for the modification of tooling in advance. Use of foaming means less material is required resulting in a 15% weight savings, fewer emissions and less cost.

OEM/Vehicle BMW 2017 Countryman System Supplier International Automotive Components (IAC) Material Processor    International Automotive Components (IAC)

Material Supplier SABIC Resin Stamax PP LGF Tooling/Equipment Supplier Siebenwurst

For More Information See: http://www.plastics-car.com/Partners/Colleges-and-Universities

Nacelle Cover

A unique soft touch and feel was achieved for this interior application, while eliminating painting (and its associated costs and environmental impact). A unique recipe with a specially -developed glass fiber and PP combination, delivering equivalent performance of painted ABS, enabled a 30% cost savings by eliminating painting. Additional cost avoidance is possible with a reduction in overall rejections that may come from use of ABS.

OEM/Vehicle Tata Motors Limited 2018 Tata Tiago System Supplier Tata Auto Components Material Processor    Abhijeet Tool

Material Supplier SABIC Resin S3625 PP Tooling/Equipment Supplier Abhijeet Tool

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

Cargo Management Deployable Shelf

This first time use of a multi-functional cargo management system in an SUV provides the customer with dynamic storage options in the rear of the vehicle. It enables the use of the full height of the cargo environment as well as assisting in solving the common customer complaint of items falling out the rear of the vehicle. The system bins, components and actuation linkages are injection molded using various PP and ABS materials to meet new appearance and load requirements.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition/Lincoln Navigator System Supplier Valley Enterprises Material Processor    Valley Enterprises

Material Supplier Chase Plastics Resin PPH5TF2 PP & HI121 ABS Tooling/Equipment Supplier Reliable & Reasonable Tool Service LLC Buiter Tool & Die, Inc.

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

Thin Wall Floor Console Carrier

This floor console carrier is unique with its 2.0 mm nominal thin wall thickness (with ability to implement lightening holes) and 40% Long Glass Fiber PP construction with first surface quality appearance. A 30% mass savings resulting in a 2.2 lb/.99 kg weight savings, and a 15% cost savings was achieved. Lateral stiffness targets were exceeded eliminating the need for metal brackets ($1.50). It is also the first time injection molding was used to process this type of a component.

OEM/Vehicle General Motors 2017 Buick Enclave, Chevy Traverse System Supplier NYX Material Processor    NYX

Material Supplier Celanese Resin Celstran 40-0453 PP GF Tooling/Equipment Supplier Integrity

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

Structural AGS w/Integrated Loose Layer Construction

This, possibly the largest 2-shot AGS in production today, was designed with an integrated locating and attaching system for consistent fit between the grille and headlamps eliminating the need for FEM assembly, dunnage and shipping. Savings are estimated at $5 per part system, additional $16 inside cost in addition to $45 markup and shipping, $1 in labor by eliminating 4 fasteners, and inplant tooling avoidance of $2 Million for a new cell and assembly tooling. A 1 lb weight savings was achieved, plus an additional 3 lb avoidance over a metal/plastic hybrid assembly.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition System Supplier Magna Plastcoat Material Processor    Magna Plastcoat

Material Supplier Celanese Resin Celstran 40-20 PP/GF Tooling/Equipment Supplier Integrity Tool

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

Integrated Fascia Stiffener

This patent-pending lower fascia (belly pan) stiffener is designed to balance the load requirements of both lower-leg pedestrian protection and low-speed damageability in a single component using a series of integrated stiffeners. Replacing plastic/metal hybrid and all-metal designs, all required features (including variations in material thickness, ribs, and various sections) are contained on the B side of the component and molded in a single tool, lowering assembly time, eliminating straps, and lowering BSR.  The stiffener removes 1.5 kg of mass and saves $2 USD/vehicle piece cost plus an additional $50,000 USD in tooling avoidance.

OEM/Vehicle Ford Motor Co. 2017 MY Ford Escape System Supplier Plastic Omnium Material Processor    Plastic Omnium

Material Supplier SABIC Resin STAMAX 2700 PP FG 40% Tooling/Equipment Supplier Basis

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

Next Generation Side-Impact Armrest

Minimizing door intrusion during side impacts usually requires intensive body-structure countermeasures. Abdomen criteria for 5th and 50th percentile dummies are primarily driven by door-trim armrest stiffness during side impacts. This new door-trim armrest improves safety as a tuning component by acting as a load limiter and absorbing energy. Comprised of a skin, foam pad, PP-nonwoven trampoline fabric, ABS armrest substrate, and PP trampoline frame, the system is significantly softer than previous designs, substantially outperforming static and dynamic functional requirements without adding countermeasures, cost, or weight. Further, armrest durability improves 6x, and costs and weight are reduced $31.80 and 3.8 kg per vehicle.

OEM/Vehicle Ford Motor Co. 2016 Ford Super Duty F250 System Supplier Yanfeng USA Automotive Trim Systems Company, Inc Material Processor    Yanfeng USA Automotive Trim Systems Company, Inc

Material Supplier LyondellBasell Resin SG702 PP Tooling/Equipment Supplier ToolPlas Systems Inc.

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

Seat Cushion Frame and Storage Door

For the first time, a polymer composite has replaced magnesium in a structural seat-cushion frame and under-seat storage lid for a front center 20% seat with integrated restraint system. The application is weight neutral and lower cost (≈$4 USD/unit), and satisfies all safety and crashworthiness requirements. Its flexible architecture allows for updates with future enhancements. Injection molded 40% LFT-PP is used to mold the frame, which also features an EPP antisubmarine foam block and a lockable ergo-latch. The assembly represents a significant reduction in carbon footprint vs. magnesium and has yielded 2 awarded and 2 pending patents.

OEM/Vehicle Ford Motor Co. 2016 Ford Super Duty System Supplier Royal Technologies Corp. Material Processor    Royal Technologies Corp.

Material Supplier Celanese Corp. Resin Celstran PP-GF40-20 Tooling/Equipment Supplier Vortec Tooling Solutions, Inc.

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