Battery Enclosure Cover

The battery pack is a stressed member and weighs 960 lbs/440 kg. It accounts for 23% of the car's value. The SMC cover is a large light weight cover that is integral to the pack. A new light weight high glass loaded Vinyl ester/Polyester blend SMC was formulated to meet the high speed stress strain requirements and, for the first time, be incorporated as part of the structural element. A 30% weight savings and a 40% cost savings, over alternative manufacturing methods (steel/aluminum stampings) was achieved.

OEM/Vehicle General Motors 2017 Chevrolet Bolt System Supplier LG Electronics Material Processor    Hanwha Corporation

Material Supplier Hanwha Corporation Resin 5145 SMC vinyl ester/ polyester Tooling/Equipment Supplier Hanwha Corporation

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

Weatherable Structural SMC Truck Bed and Trunk Box

The bed, tailgate, in-bed trunk, and cover on this pickup are compression molded in a new weatherable, UV-stable, MIC, structural SMC using unsaturated polyester resin.  In-mold black coloring plus texturing are used to eliminate paint and the need for bed liners plus minimize the appearance of scratches and dings. The lockable trunk is a single molded SMC part that can be converted to a watertight cooler. Extensive development work was done to improve the UV resistance of SMC materials, which traditionally have not been weatherable.

OEM/Vehicle Honda Motor Co. 2017 Honda Ridgeline System Supplier Continental Structural Plastics Material Processor    Continental Structural Plastics

Material Supplier Ashland Inc. Resin Arotran 805 Unsaturated Polyester Resin Tooling/Equipment Supplier Century Mold

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

Closed-Loop Recycling of Bottles

This innovative, multi-stakeholder, cost-neutral recycling project protects the environment, grows local economies, creates jobs, and helps people in a sustainable manner. Water bottles collected at GM operations and from the Flint, Michigan area are directed into a supply chain that recycles the material into nonwoven fleece for specific applications including engine manifold cover insulation, insulation for coats that convert to sleeping bags for the homeless and are made by formerly homeless women as part of a jobs program, and air filters that purify the air at numerous GM and other manufacturing operations. Already 3.5-million water bottles have been repurposed.

OEM/Vehicle General Motors Co. 2016 Chevrolet Equinox, GMC Terrain System Supplier Exo-S Material Processor    Rogers Foam Co.

Material Supplier Wm. T. Burnett & Co. / Palmetto Synthetics LLC Resin Polyester

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

Low Specific Gravity Carbon Fiber/Glass Hybrid SMC

To reduce weight while using the same tooling for a special-edition Corvette sportscar, 2 distinct composites were formulated  ̶  a high-strength carbon and glass-fiber-reinforced polyester-based SMC and a lower-density, glass and carbon fiber-reinforced polyester liquid compression molding composite, both with a unique spiral-shaped nanoplatelet technology.  The parts met the mechanical requirements of existing materials and provided the same shrink properties without cycle-time or tool changes, all while saving more than 15% weight for this convertible sportscar.

OEM/Vehicle General Motors Co. 2013MY Chevrolet Corvette System Supplier Molded Fiberglass Co. Material Processor Molded Fiberglass Co.

Material Supplier Molded Fiberglass Co. Resin iNVENTA 753 Polyester Tooling/Equipment Supplier Century Tool & Gage

For More Information See: http://www.plastics-car.com/Tomorrows-Automobiles/Current-Projects

Electronic Throttle Control Module

This is the first plastic ETC housing, which replaces machined cast aluminum at mass savings of 28% and costs savings of 18%, while also reducing warranty costs and potential for ice freeze-up and potential throttle blade stick. A special zero-shrink BMC grade was used and the units tight concentricity better controls air flow at idle.

OEM/Vehicle 2007 Chrysler ® Pacifica ® cross-over vehicle by Chrysler LLC  System Supplier Bosch Material Processor Christophery

Material Supplier BMC Inc. Resin TetraDUR BMC TD 455 BMC thermoset polyester Tooling/Equipment Supplier Christophery

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

Low-Mass SMC Hoods

This lower density, tough, Class A SMC maintains the physical properties of standard SMC at 20% lower filler loadings via the use of nanoclay reinforcements.  This lowers specific gravity from 1.9 to 1.55, reducing part weight, increasing hauling capacity of a truck 21 lb/9.5 kg per trip without exceeding load limits, and increasing productivity for a fleet owner by $2-million USD/year.

OEM/Vehicle 2008MY Navistar Inc. International® TranStar® Class 8 Truck  System Supplier Core Molding Technologies  Material Processor Core Molding Technologies

Material Supplier Ashland Inc. Resin AROTRAN®  720/722  Unsaturated Polyester

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

Instrument Panel with Seamless Airbag

This hand-stitched & hand-wrapped topper panel with passenger airbag (PAB) door significantly reduces cost ($110 USD) and mass (10 lb / 4.5 kg) vs. previous technologies, while improving vehicle craftsmanship.  A polyurethane skin is laminated to a polyester spacer fabric, then attached to a polypropylene substrate; both skin & substrate are simultaneously laser scored to produce the PAB door using an “H” pattern that eliminates out-of-position concerns.  Additionally, a molded-in-color TPO defroster grill is sonically welded to the substrate and the airbag chute and door are attached via vibration welding with neither exhibiting read-through.

OEM/Vehicle 2009MY Ford Motor Co. Lincoln® MKS Sedan System Supplier Automotive Components Holdings Material Processor Automotive Components Holdings – Saline

Material Supplier Advanced Composites Resin PUR, PP, & Polyester

For more Information See: http://www.plastics-car.com/InstrumentPanels

Impact Blocker for Fuel System Protection

This compression-molded, SMC part provides impact protection for a diesel-engine fuel pump.  A new application for thermoset composites, it replaces die-cast metal and nylon for a 50% weight savings (vs. metal) and a 50% cost reduction.  Compression-molded SMC brought short tooling lead times, excellent dimensional tolerances, and impact strength that exceeded both metal and nylon.

OEM/Vehicle Chrysler Group LLC 2010 Jeep Wrangler System Supplier VM Motori S.p.A. Material Processor Premix Inc.

Material Supplier Premix Inc. Resin Premi-Glas 1286 Hybrid Vinylester / Unsaturated Polyester SMC Tooling/Equipment Supplier Witco Tool & Die

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Powertrains/Transmissions.html

Anti-Stain Finish for Cloth Seats

Materials that typically soil and stain cloth are easily cleaned off even after significant wear takes place. Moisture-barrier, antistatic, and odor-resistant properties are also retained after wear.  The improved fluoroalkyl resin coating uses the same pad/spray application method as previous technology while reducing costs 15%.

OEM/Vehicle Hyundai-Kia Automotive Group 2011 Hyundai Soul CUV & Kia Optima mid-size sedan System Supplier Kolon Glotech Inc. Material Processor Kolon Glotech Inc.

Material Supplier Kolon Glotech Inc. Resin Cleantex Innoclean Polyester Tooling/Equipment Supplier Kolon Glotech Inc.

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

Power Window Motor Output Gear & Shaft

This power-window motor changed from a steel output pinion to a new injection-molded polyester one for a quieter/lighter motor to meet customer targets while still complying with window velocities. It is industry’s first plastic output pinion that ensures functionality.  Additionally, the design allows for regulator plug-‘n-play capability into the power drum for better motion control.  Packaging of the involute onto the spline gear to the accommodating drum spline was critical to the customer.  The application saved $450,000 USD direct and $250,000 USD indirect cost savings annually.

OEM/Vehicle Ford Motor Co. 2011 Ford Focus compact car System Supplier Brose Fahrzeugteile GmbH & Co. KG Material Processor Mitsuba Corp.

Material Supplier DuPont Automotive Resin Hytrel TPC-ET Polyester Tooling/Equipment Supplier Camoplast Inc.

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