D Pillar

This is an Industry-first use of a polycarbonate copolymer material on a D Pillar. Improved impact performance vs. PMMA was achieved and it allowed for rivet attachment to the vehicle without failure during environmental testing. The material demonstrated good UV, heat, and gloss performance. The material change also made it possible to achieve a high gloss piano black mold-in-color to OEM standards.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition System Supplier Windsor Mold Group Material Processor    AUTOPLAS

Material Supplier SABIC Resin LEXAN SLX 2271T PC Copolymer Tooling/Equipment Supplier Windsor Mold Group

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

Paint Racks with Robber Bars for Electrostatic Paint Line

This painting process uses racks with “Robber Bars" to attract paint and reduce over-spray on the backside of the plastic part during the painting process (generating squeak issues). The bars on the backside of the racks attract the paint of the electrostatic paint line and help to prevent over-spray, reducing VOCs due to less use of paint and eliminating the need for the manual masking process. This results in a cost save of $.24 per vehicle and can be translated to all electrostatic paint lines for plastic components.

OEM/Vehicle Ford Motor Company 2018 Ford Fusion System Supplier Flex-N-Gate

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

Torsional Welding of PDC Sensors to Thin Wall Fascia

This is the first application of torsional welding (spin & ultrasonic welding combined) on automotive fascias. It allows welding of PDC brackets without localized thickening of wall stock on 2.5 mm, thin wall, molded fascias. An adjustable TPO material with high melt flow, high stiffness/ impact allowed for less material to be used resulting in a 10% reduction in mass for a 7% weight savings with $122,000 direct cost savings in three years. Cycle times were improved and there was no weld read through resulting in a quality appearance. Future applications or this process include fascia support brackets, fog brackets and more.

OEM/Vehicle Volkswagon AG 2018 Skoda Octavia System Supplier Magna Exteriors Material Processor    Magna Bohemia Liberec

Material Supplier SABIC Resin Sabic 8650 TPO Tooling/Equipment Supplier Changzhou Huawei Mold Co., Ltd.

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

Integrated Sliding Armrest and Hinge Assembly

Additional console stowage volume with a lid held open to any position (like a laptop screen) is achieved with this single Injection molded upper bin and lid inner using a torque insert to create hinge for the armrest. It includes Integrated attachments for a sliding armrest that is interchangeable with a fixed armrest. Using a robotic arm, the torque insert hinge is placed into the cavity of the mold and over-molded with 30% glass-filled nylon 6. Upon mold close, the seal off around the hinge allows for the upper leaf and lower bin to be independently injected at the same time (using sequential valve gating), producing 2 complete assemblies in one press cycle. This eliminates the need for metal hinge systems saving $4.50 and 2 lbs weight per unit

OEM/Vehicle Ford Motor Company 2017 Ford EcoSport System Supplier Faurecia Interior Systems Material Processor    M & N Plastics

Material Supplier BASF Corporation Resin Ultramid B3EG6 30% GF PA 6 Tooling/Equipment Supplier M & N Plastics

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

Two Shot Interior Decoration Bezel

This unique 3-D decorative effect was achieved with 2K 'reverse' injection molding (1st shot tinted PC) with overmolding of grained surface with 2nd shot (self colored pigmented ABS). This is the first time this process was used to achieve the 3-D visual effect (color and texture) for a part of this size and geometry. A 30% cost save was achieved vs IMD/IML/high gloss painting and there was a 20% scrap reduction vs conventional 2-layer high gloss piano black appearance.

OEM/Vehicle Ford Motor Company 2018 Ford Fiesta System Supplier Faurecia Interior Systems Material Processor    Faurecia Interior Systems

Material Supplier Lotte Advanced Materials Resin INFINO LT1220 PC Starex LX0760 ABS Tooling/Equipment Supplier JP Grosfilley SAS

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

Winged Spring Clip with 4 Way Locator

Metal clips and springs were eliminated by designing an in-molded W shaped plastic clip with a 4-way locator providing efficient attachment per requirements and eliminating additional costs for fasteners and assembly. The plastic part comes out of the tool with the clips molded in. The patented winged spring clip design locates, locks and retains in a single snapping action. A cost save of $0.17 per clip/$2.19 per vehicle resulting in $250K per year; and a 10% weight saving is achieved.

OEM/Vehicle Ford Motor Company 2018 Expedition/Navigator System Supplier Magna Seating Material Processor    Royal Technologies

Material Supplier Advanced Composites Resin ADX 5017 TPO Tooling/Equipment Supplier Tri Tech Tooling, Inc.

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

Part via Preform (PVP) Assembly Carrier

Part via Preform (PvP) technology enables economical production of carbon fiber reinforced plastic (CFRP) automotive parts. The carbon fiber has been binder-modified to be sprayed into near-net shape preforms without intermediate textile processing resulting in a 30% cost save. High fiber volume content (50% Vf), delivers high mechanical properties. The process can create complex shapes with homogenous material and can be combined with aligned fiber placement (AFP) for part reinforcement. Resin injection of PvP preforms works with high pressure resin transfer molding (HP-RTM) including an inmold coating step to provide for easy surface painting. The binder on the carbon fiber can be activated, allowing for greater design freedom, and ability to assemble preforms and achieve local thickness variations to exacting specs.

OEM/Vehicle Volkswagon AG 2016 Porsche GT3 Cup II System Supplier Toho Tenax Material Processor    Toho Tenax

Resin Epoxy

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

Assisted Positive-Locking Junction Box

This tool-less, single-lever, self-locking underhood bussed electrical center (UBEC) guarantees proper connections for 4 connectors from 4 different wire harnesses using 1 hand and low assembly effort. There is no need to re-orient the UBEC to install mating connectors during OEM assembly. The result is a robust, high-circuit-capacity design that s ergonomically friendly to assembly-line workers. Additional benefits are a 7% weight savings, 8% additional spare electrical content, 10% reduction in overall footprint, better water-ingress protection, and 30% less assembly time.

OEM/Vehicle General Motors Co. 2016 Chevrolet Camaro System Supplier Yazaki North America Inc. Material Processor    Yazaki North America Inc.

Material Supplier DuPont Automotive Tooling/Equipment Supplier Yazaki North America Inc.

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

Power Head Restraint Guide-Sleeves

This project created robust modular assembly features to allow quick connection of electrical connectors/wiring at lower cost for the power head restraint system. By integrating the electrical connector receptacle and wiring assembly into the injection molded POM guide sleeves, proper connector alignment is assured and power head restraints can be assembled in a similar manner and time as manual head restraints. This reduces assembly time, complexity, investment, and quality issues and has led to 2 patents being filed.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Grammer AG Material Processor    Treck Plastics

Material Supplier DuPont Automotive Resin Delrin 100 Acetal Tooling/Equipment Supplier HS Die & Engineering

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

Robotic Laser Cutting & Welding of TPO Fascia

A hydraulic punch and sonic welding operation was replaced by robotic laser cutting and welding of a Class A exterior fascia. Unlike other welding processes, it is not necessary to thicken wallstock in weld areas to prevent read-through with robotic laser welding of brackets on the backside of the part, and that reduces weight slightly. It also eliminates the need for contoured horns and punches. Clean cuts can be made in 1 sec on the painted side of the part. The dual-function process provides greater flexibility between programs and reduces floor space and tooling costs.

OEM/Vehicle General Motors Co. 2017 Chevrolet Camaro ZL1 System Supplier Magna Exteriors, Inc. Material Processor    Magna Exteriors, Inc. - DexSys

Material Supplier LyondellBasell Resin Hifax TYC1168X TPO Tooling/Equipment Supplier Jenoptik AG

For More Information See: http://www.plastics-car.com/Recycling-of-End-of-Life-Vehicles

Carbon Core Structural Components

Carbon fiber-reinforced fast-cure epoxy and high-pressure RTM and liquid compression molding (LCM) are used to produce 27 CFRP parts for the vehicle's mixed-material BIW structure to support production volumes of 80,000+ vehicles/year. The HP-RTM roof arc follows the shapes of the car body and offers an outstanding weight/performance ratio. The LCM tunnel reinforcement improves the vehicle's torsional stiffness and is produced in <1 min. These "carbon core" parts replace metal, improve stiffness, ride/handling, and safety while reducing vehicle mass 40 kg for better fuel efficiency and tailpipe emissions.

OEM/Vehicle BMW Group 2015 BMW 7 Series Sedan System Supplier BMW AG Material Processor    BMW AG

Material Supplier Hexion Inc. Resin EPIKOTE/EPIKURE Epoxy

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

Laser Ablation to Improve Bond Adhesion

Previously used to clean mold surfaces in the composites industry, a modified laser system is used to improve bond adhesion on composite parts. Replacing hand sanding, the robotic laser-ablation program reduces labor, benefits industrial hygiene (no dust, self-contained system), improves consistency and repeatability, shortens cycle time, eliminates perishable items (e.g. masks, sandpaper, and wipes), and lowers cost an average of 15%.  The system's flexibility permits program path, angle of attack, and energy level to be customized for each part's unique material and geometry. 

OEM/Vehicle General Motors Co. 2016 Chevrolet Corvette System Supplier Molded Fiber Glass Companies Material Processor    Molded Fiber Glass Companies

Tooling/Equipment Supplier Adapt Laser Systems LLC

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

A/C Register Chrome Vane Cap

Chrome-plated ABS vane caps with a contoured edge create unique styling and a new decorative finish to A/C register vanes without jeopardizing vane surface appearance. An automated process is used to apply adhesive bonding material to the vane cap and then assemble the vane to the GR-PBT vane body with zero-gap margins for excellent fit & finish. The process eliminates appearance defects due to mechanical locks on the vane body and permits parts to be handled within 20 seconds.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Summit Polymers, Inc. Material Processor    Summit Polymers, Inc.

Material Supplier Samsung Group / Toyobo Resin MP-0160R ABS Vylopet EMC-450 PBT Tooling/Equipment Supplier Isen Tooling & Engineering Co., Ltd. Sunway Automotive

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

Two-Shot Map Lamp Lens

A redesigned capacitive touch lens produced via 2-shot molding eliminates molding defects while maintaining an ideal bonding surface and clear aperture for best light intensity. Eliminating a second tool, the Fresnel pattern is molded into the core of the first shot, which becomes the cavity of the second shot as the latter is layered over the former, keeping both outer surfaces smooth. Using 2 grades of PC with a 40o difference in HDT solves the problem of the second shot melting the first during overmolding. Eliminating a tool reduced costs 25%.

OEM/Vehicle Ford Motor Co. 2017 Lincoln Continental System Supplier Flex Auto (Flextronics) Material Processor    Flex Auto (Flextronics)

Material Supplier SABIC Resin Lexan 143R, HFD1830 Polycarbonate Tooling/Equipment Supplier Flex Auto (Flextronics)

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

Hot Gas Welded Thermostat Housing Assembly

Hot-gas welding joins both halves of this 35% GR-PPA thermostat housing assembly. The part has a small welding-flange footprint but high weld strength because there is no fiber/material degradation during the joining process. In fact, it is the only welding process that permits bridging of glass across the joint. The weld distance is held within 0.1 mm, enabling parts to package into very limited spaces with tight tolerances. Since the part is not touched during welding, there is no sticking. Versus previous aluminum solutions, the PPA assembly is 30% lighter and 40% less costly.

OEM/Vehicle Ford Motor Co. 2017 3.5L V6 Cyclone TiVCT GTDI engines System Supplier Plastic Tec - Bocar Group Material Processor    Plastic Tec - Bocar Group

Material Supplier DuPont Automotive Resin Zytel HTN51G35HSLR BK420 PA Tooling/Equipment Supplier Schweiger GmbH & Co. KG

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