Shaker Scoop

This structural component had to meet Class A body panel styling requirements, increase horsepower, reduce acoustics, mass, and cost, and meet all the fatigue, impact, environmental, and thermal requirements of air-induction system components and still be moldable. The resulting assembly is an important visual focal point of the vehicle, yet is approximately 65% lighter and 60% lower cost than die-cast aluminum.

OEM/Vehicle Fiat Chrysler Automobiles 2014 Dodge Challenger Shaker sports car System Supplier North American Assembly Material Processor Molding Technologies Inc.

Material Supplier Magna International Inc. Resin EB-323 Class A SMC Tooling/Equipment Supplier Penco Tool Inc.

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

Integrated Front End Module System

Compression-molded SMC was used on the first North American implementation of integrated front-end module (FEM) systems for cost, weight, and functional performance. Switching from metals allowed for significant parts consolidation, eliminating 22 major subcomponents and 27 fasteners/vehicle plus related design drawings/CAE models, stamping tools, gauges, fixtures, plus purchasing and logistical tasks. The single-piece 'ready-to-install' structural carrier with self-locating fasteners improved assembly operations, provided an 'open architecture' for powertrain installation, eliminated 9 line locations and 15 work-cell locations, reduced weight 22% and costs 14%, while boosting quality (R/1000) 22% vs. previous designs. Additional benefits included improved serviceability and documented reductions in collision insurance costs while meeting all safety requirements.

OEM/Vehicle Ford Motor Co. 1996 Ford Taurus & Mercury Sable sedans System Supplier Toledo Mold & Die Material Processor Budd Plastics Division

Material Supplier Budd Plastics Division Resin SMC

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

Trunk Divider Panel

This is the first mid-trunk modular / removable divider system for a passenger vehicle application.  The panel forms 2 compartments in the trunk (one hidden), has integral hooks for grocery bags, provides fold-flat design for wet / dirty item storage, and is removable for use outside vehicle. This solution met all cost, mass, performance, design, and functional requirements.

OEM/Vehicle 2007 Nissan ® Sentra ® compact car by Nissan Motor Co. System Supplier Meridian Automotive Systems Material Processor Meridian Automotive Systems

Material Supplier Meridian Automotive Systems Resin SMC Tooling/Equipment Supplier Radiance Mold

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

Battery-Cover Assembly

This 1-piece, compression-molded battery-cover assembly in sheet-molding compound (SMC) covers and seals the battery packs as received and is designed to protect the batteries and maintain a hermetic seal even in the event of a severe crash.  Special low/mid density SMC was developed for this application, saving an estimated 1.13 kg vs. standard SMC.  The part also features installed hardware seals, a reflective foil covering, and 73 openings to fasten the cover to the battery tray on this electric vehicle.

OEM/Vehicle General Motors Co. 2011 Chevrolet Volt System Supplier GM Brownstown Material Processor Continental Structural Plastics

Material Supplier Continental Structural Plastics Resin Low/Med. Density SMC Tooling/Equipment Supplier Century Tool & Gage

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

Composite Valve Cover Assembly with Oil Trap

This first metallic top-coated SMC valve-cover assembly with deep draw and die-locked features meets all requirements for Volvo Powertrain – North America.  Use of SMC allowed for significantly reduced investment, with 30% mass saving and 50% piece-cost savings vs. a cast-aluminum design.

OEM/Vehicle 2006 MY Volvo Powertrain Mack® Vision, Granite, and MR System Supplier Meridian Automotive Systems Material Processor Meridian Automotive Systems

Material Supplier Meridian Automotive Systems Resin SMC Tooling/Equipment Supplier Concours Mold

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

Removable Hard Top with "Freedom Panels"

"Freedom Top" SMC panels provide 8 unique design and styling configurations for this composite roof module.  All main panels achieve a Class-A finish on the interior via molded-in-color, as well as Class-A finish on the exterior via spatter coating.  Structure is derived from bonded inner "picture frames" that also house all necessary latching hardware and seals.  The molded roof panels achieved a significant cost and mass savings vs. traditional metal roof structures while offering more configurations for use.

OEM/Vehicle 2007 MY DaimlerChrysler Jeep®  Wrangler System Supplier Meridian Automotive Systems Material Processor Meridian Automotive Systems

Material Supplier Meridian Automotive Systems Resin SMC Tooling/Equipment Supplier Century Tool

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Auto-Body-Exterior/Auto-Trim.html?css=print