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

Precise Integration Enabled System

The precision integration-enabled system is a patented locating and attachment feature that minimizes gaps or movement as well as manufacturing variation common with snap fits while leveraging the inherent elastic deformation properties of plastic.  No external fixtures are needed, labor is reduced, and ergonomics are improved. This is the first application to use a MIC bezel for the housing that prevented water migration without need for additional seals. Also, the typical tooling action needed to mold snap fits was eliminated, saving tooling time and costs.

OEM/Vehicle General Motors Co. 2015 Chevrolet Volt System Supplier ITW Deltar Material Processor    ITW Deltar

Material Supplier Celanese Corp. Resin MetaLX Hostaform POM Tooling/Equipment Supplier ITW Deltar

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

Lower Rocker Panel

This gas-counterpressure structural-foam molded 1-piece rocker panel has Class A surfaces front and back, solves gap and fit issues, and eliminates the need for fasteners on the back. The fully recyclable 15% talc-filled TPO eliminates 5 previous components, eliminates warpage, and shows no surface porosity or sink marks. It offers increased strength and passes all high-speed flutter tests, achievable with variable wall thicknesses thanks to gas-counterpressure.  The final product eliminated 100% of the assembly labor and components in the earlier multi-piece design and offered the highest quality and durability at the lowest cost and weight.

OEM/Vehicle Ford Motor Co. 2016 Mustang Shelby GT350R Hummingbird System Supplier Flex-N-Gate Material Processor LyondellBasell Reedy International Corporation

Resin Hifax TYC852P TPO SAFOAM Foaming Agent Tooling/Equipment Supplier Concours Mold Inc.

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

Blow-Molded Air Deflector

This blow-molded 1-piece air deflector, mounted near the wheels to deflect air, improve fuel efficiency, and reduce dirt and ice retention, replaced a 2-piece injection-molded deflector. An innovative blow-molding technique involving high pressure and high vacuum in the tool enabled uniform wall stock and fine-texture graining on both sides of the part to help it harmonize with nearby injection-molded parts. A special blow-moldable TPO grade was developed to maintain impact and ductility to -30C at lower density. Vs. the earlier injection-molded design, mass was reduced 5%, tooling costs were lowered, and a welding operation was eliminated.

OEM/Vehicle General Motors Co. 2014 GMC Sierra & Chevrolet Silverado System Supplier Metelix Products, Inc. Material Processor Metelix Products, Inc.

Material Supplier Washington Penn Plastics Co., Inc. Resin 7622LW UV 598F TPO Tooling/Equipment Supplier Metelix Products, Inc.

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

Engine-Room Partition Wall

This all-plastic engine-room partition wall provides excellent sound insulation between engine and passenger compartments thanks to the use of long-glass PA 6/6 with barium sulfate.  Replacing stamped steel plus a sound-deadening pad, the patented injection-molded plastic partition reduces engine noise 8 dB, lowers part count and assembly time, and offers a 20% weight reduction without increasing costs.

OEM/Vehicle Hyundai Motor Group 2015 Hyundai Genesis System Supplier NVH Korea Material Processor NVH Korea

Material Supplier KOPLA Resin KOPLA KDX 1065 PA66 Tooling/Equipment Supplier Hyundai Motor Group

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

Push-to-Release Exterior Fastener

Compared to other easy-service fasteners, which have twist heads to release, this injection-molded PA 6/6 fastener only requires that you push the center pin to the service position to remove. This fastener cannot back out or be removed from the installed position without deliberate actions by the customer. The pin and body are designed to not be easily separated; however, the fastener is reusable, unlike other push pins that become damaged in the process of removal. It meets EU lamp serviceability requirements, reducing the time needed to remove the fastener by 90% without tools.

OEM/Vehicle                   Ford Motor Co.             2015 Ford Mustang System Supplier ITW Deltar Fasteners

Material Supplier Ascend Performance Materials, LLC Resin PA 6/6 Tooling/Equipment Supplier A&P Tool, Inc. & M&M Tool and Mold, LLC

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

Louvered Side Window

This first-to-market application features 3 glass panes encapsulated via PVC injection molding to create a louvered panel for the rear quarter window replacing metal. Glass panes are held in place with the rigid injection molding framework creating a high-tech appearance that can be seen through. It also reduces wind noise and drag, lowers mass and costs, and speeds assembly time.  Low-pressure, multi-gate tooling and the ability to locate and retain the 3 glass panels during the injection-molding process were all key to the success of this application.

OEM/Vehicle Ford Motor Co. 2014 Ford Mustang 50th Anniversary Edition System Supplier Magna Engineered Glass Div. Material Processor Magna Engineered Glass Div.

Resin PVC

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

Seamless Flipper Window

To accommodate multiple roof heights and wheelbase length options on this van while providing customers with an uninterrupted glass appearance for both fixed and moveable windows (with no exposed hardware and a low-profile inside latch), a hole-in-glass, window-within-a-window concept was used.  A separate flip-glass panel is bonded to glass and assembled to an injection-molded engineered plastic framework, which carries the sealing and water-management system. This enabled a single flange configuration to be used for either fixed or moveable window options. Significant weight and cost savings plus assembly time reductions were achieved vs. traditional designs while also improving fit-to-body and achieving best-in-class sealing and water management.

OEM/Vehicle Ford Motor Co. 2014 Ford Transit van System Supplier Magna Engineered Glass Div.

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

Door Outer Belt Moldings

To answer design restrictions of traditional outer belt moldings (typically formed of extruded rubber or TPV, which limits the belt to a single profile along the length of the part), a 2-shot injection molding and heat-staking operation were used to create an outer belt with variable width.  The Class A material (rigid carrier plus TPV overmold) is color matched and grained for harmony with other exterior ornamentation. The combo also provides thermal stability critical for flush fit to the door cutline at the B-pillar ends. In addition to improve fit, weathering, and design freedom, mass was reduced 46% and assembly time was reduced, contributing approximately 18% indirect cost reduction.

OEM/Vehicle Ford Motor Co. 2014 Ford F-150 pickup System Supplier Henniges Automotive Material Processor SRG Global, Inc.

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

Flush Glass Power Backlite

This first-to-market hole-in-glass seamless sliding back window with engineered plastic framework addresses previous sealing and aesthetic issues with conventional complex multi-pane constructions for the pickup market. The result is improved appearance, styling, and operating performance that meet customer wants while providing best-in-class sealing and water management, plus significant weight and assembly savings vs. traditional designs at similar costs. Further, a heated version and flush design maximize line of sight for drivers while providing the studio greater design freedom.

OEM/Vehicle Ford Motor Co. 2014 Ford F-150 pickup System Supplier Magna Engineered Glass Div. Material Processor Magna Engineered Glass Div.

Resin PVC

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

Foot Step

By replacing metal with injection-molded LFT-PP, it was possible to reduce weight by more than 50%, eliminate corrosion and the cost and environmental impact of paint, improve cold-temperature impact, scratch resistance, and weatherability, and integrate the upper step with the front fender (eliminating assembly and reducing part count) on these commercial trucks in China.

OEM/Vehicle JAC Motors 2015 N211 light-duty truck System Supplier Suzhou Wanlong Group Co. Ltd. Material Processor Suzhou Wanlong Group Co. Ltd.

Material Supplier Celanese Resin Celstran PP-GF40 LFT-PP Tooling/Equipment Supplier Suzhou Wanlong Group Co. Ltd.

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