Next Generation Sustainable Content Bio Foam

This application provides a sustainable alternative to conventional petroleum based foams - at a lower weight and cost with more design flexibility. Caster based foam provides for a lower molded density and ability to be foamed in as little as 4 mm cross sections, and superior bond strength to mating materials. Foam in place tooling, where a cast PVC, TPE, or TPU skin is placed in the mold with a hard plastic retainer and the foam is injected between these two components, is used for processing. A weight savings of 20 - 40% (depending on foam thickness) and a cost savings of $2 per average foamed in place instrument panel is achieved.

OEM/Vehicle Ford Motor Company 2018 Ford Fusion System Supplier International Automotive Components (IAC) Material Processor    International Automotive Components (IAC)

Material Supplier BASF Corporation Resin Elastoflex 3496/102 Resin, 113/4 Iso PU

For More Information See: http://www.plastics-car.com/Recycling/Life-Cycle-Use-Phase-of-a-Cars-Life

Cut and Sew IP Top Pad

Cut & Sew PUR was laminated to an injection-molded LFT-PP retainer, then coupled with an innovative scoring technology to provide for seamless passenger airbag deployment while improving styling flexibility and enhancing appearance on this instrument panel. Cut & Sew PUR is a cost-effective solution for vehicle builds under 100,000 units, offering weight and cost savings, improved NVH, and the option for stitching and 2-tone colors to enhance perceptions of craftsmanship.

OEM/Vehicle 2008 Cadillac CTS ® sedan by Chrysler LLC  System Supplier Dräexlmaier Automotive Material Processor Dräexlmaier Automotive

Material Supplier Benecke & Ticona Engineering Polymers Resin Benova ® PU Celstran ® 30% LGF PP Tooling/Equipment Supplier HS Die

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

Molded-in Faux Stitching

The realistic appearance of a hand-wrapped leather insert with French and Coach seams was achieved on this door panel using a 1-piece molded spray urethane part without need for separate operations. The realistic appearance of leather stretching, bunching, and stitching is achieved via a silicone mold cast from leather originals. Each of the vehicle’s four-door panels retains its own unique bunching and stretching pattern, yet each panel is absolutely repeatable vehicle-to-vehicle. The result is a $50 USD/vehicle cost savings, better quality, perfect repeatability, and greater durability.

OEM/Vehicle 2010MY Ford Motor Co.: Ford®   Taurus® Sedan System Supplier Ford Motor Co. Material Processor Automotive Components Holdings

Material Supplier BASF & Red Spot Paint Resin Elastoskin® 50555 PU Tooling/Equipment Supplier Frimo

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

Recycled Polyol for Seat Foam

This is the first industrial production application of flexible urethane seat foams produced with polyols manufactured from post-industrial scrap foam.  A two-stage, closed-loop recycling process converts the scrap foam back into a polyol product, reducing waste going to the landfill and allowing up to 10% recycled content in new parts.  A unique process to reformulate the reclaimed polyol to meet OEM specs was also developed for this application.  Neither weight nor direct cost were negatively impacted and an estimated $348,000 USD indirect cost savings was achieved, along with reduced CO2 and landfilling.

OEM/Vehicle Chrysler Group LLC 2011 Jeep Grand Cherokee System Supplier Magna Seating of America Material Processor MS Chemical Technologies (Magna)

Material Supplier InfiChem  Polymers LLC Resin InfiGreen 320 PU

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