Thermoplastic Polyolefin Skin Instrument Panel

The use of TPO skin was recognized in the industry in 1999, when GM won the SPE® Most Innovative Use of Plastics Award in the Body Interior category. It improved safety by enabling air bag deployments, and reduced windshield fogging with the reduction of VOCs and odors without plasticizers and toxic stabilizers. The environmentally friendly all polyolefin system also enabled closed loop recycling and the replacement of PVC while reducing mass 10%. The TPO skin also improved interior quality by preventing brittle cracking, color fading (UV protection is improved by 4 times) and warping. Overall esthetics were improved by the dry haptic leather-like feel inherent in TPO skin.

OEM/Vehicle General Motors 2000 Pontiac Bonneville System Supplier Inteva Products LLC (Delphi Interior Systems) Material Processor    Inteva Products LLC (Delphi Interior Systems)

Material Supplier Mytex Polymers Resin TPO

For More Information See: http://www.plastics-car.com/Tomorrows-Automobiles/Current-Projects/End-of-Life-Vehicle-Recycling.html?css=print

Volt Battery Impact Shield

This low cost, simple crash barrier protection shield boasts rapid development and implementation with innovative materials and molding. Six parts were molded together as one mold, requiring calculating the materials reaction when secondary waterjet cuts out each piece. Three composite material constructions were tested (polypropylene with 40%, 50% then 60% glass) while tooling and 12 sets of prototype parts were developed over a 6 week period. A test vehicle was crashed, with production intent parts, passing all

test criteria the following week. Production tooling and fixtures were also completed during that time (week 7). Full production was initiated in week 12. A 75% mass and 60% cost saving vs traditional high strength steel stamping with metal fabrication was achieved.

OEM/Vehicle General Motors 2017 Buick Enclave System Supplier CSP Teijin Material Processor    CSP Teijin

Material Supplier Quadrant Plastic Composites Resin GMTex X103F61-4/1-0/90° PP Tooling/Equipment Supplier Laval Tool and Mould

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

Energy Absorbing Collapsible Glove Box Bin

This bin, that holds and stores the owner's manual, collapses during impact to prevent severe femur loads while providing a beautiful flocked appearance. The new design provides a 400 gram weight savings while lowering femur loads from unacceptable to 5-star compliant. The support structure is injection molded with a
compressed PET internal shell. This 100% recyclable, patent pending, concept can be used on any vehicle line to address high femur load issues and assist in achieving a 5-star crash rating.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition System Supplier Detroit Manufacturing Systems Material Processor    Detroit Manufacturing Systems

Material Supplier Advanced Composites Resin Basell - SG702 PP Tooling/Equipment Supplier Lamko Tool & Mold

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

All Plastic Hood Leveler

This industry first all plastic hood leveler helps to manage pedestrian hood/ head impact to reduce head trauma. It features a light weight design, OEM snap-in quick assembly, preset and adjustable height, and is recyclable. A 50% weight savings and a 35% cost savings is estimated compared to current steel/plastic/rubber hood levelers. The snap-in base is Acetal for a strong snap feature and no squeak against the Nylon post. The threaded post is nylon for strength and low moisture dimensional influence. The over-molded bumper is TPE for no squeak on the inner hood and additional energy management. The interaction of the three chosen polymers allow for required use of their individual properties and also the collaborative energy management response as they work together to help reduce head impact trauma from beneath the hood inner upon a low speed pedestrian contact.

OEM/Vehicle Ford Motor Company 2018 Lincoln Navigator System Supplier MacLean-Fogg, Engineered Plastic Components, Inc. Material Processor    MacLean-Fogg, Engineered Plastic Components, Inc

Material Supplier DuPont Automotive, ExxonMobil Resin Zytel 70G33 PA66, Delrin 100 POM, Santoprene SA60 TPE Tooling/Equipment Supplier Elite Tool & Die

For More Information See: http://www.plastics-car.com/Tomorrows-Automobiles/Automobile-Designs-of-the-Future?css=print

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

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

Engine Coolant Control Valve

This unique product design allows good fluid control and low coolant leakage at the seals on the valve moving components. Dimensional control is provided through innovative molding and assembly processes with the combination of PPA and PPS materials. A 1 lb weight savings and 20% cost savings is achieved, compared to a metal part. An approximate 2% increase in fuel efficiency and reduced emissions result in a reduced carbon foot print.

OEM/Vehicle FCA US LLC 2016 GME-T4 (Alfa Romeo - Guilia/ Stelvio) System Supplier ITW Powertrain Components Material Processor    ITW Powertrain Components

Material Supplier Dupont Automotive Resin Zytel HTN 51G35HSLR BK420 PPA

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

Transmission Baffle

Unique part geometry and CFD (Computational Fluid Dynamics) studies led to the design of this new baffle for injection molding enabling seal elements and fluid flow passages for improved transmission performance - not possible before in a stamped metal component. Transmission efficiency was improved by 8% resulting

in up to 0.5 mpg economy. A reduction of 50% in weight and 40% in cost ($1 per transmission) was gained compared to a metal part with molded seal elements. The TPE material is recyclable reducing its carbon footprint.

OEM/Vehicle Ford Motor Company 2018 Ford Focus System Supplier Ford Material Processor    Toledo Molding and Die

Material Supplier Dupont Automotive Resin Hytrel 7246 TPE Tooling/Equipment Supplier Toledo Molding and Die

For More Information See: http://www.plastics-car.com/s_plasticscar/fuel_economy/Default.html

Carbon Fiber Torque Tube

This CFRP torque tube is unique in its performance, complexity, dimensions and manufacturing process and has been developed for extreme lightweight construction and vehicle performance. Extreme lightweight construction (-40%), highest stiffness and NVH performance, high safety reserves, temperature load up to 200 degrees, and monolithic implementation of the complex structure in a one-shot production step. It was produced with a new process (first time in auto industry) that is a combination of resin transfer molding and a process from blow molding flexible tubes. The component was inflated in the interior of the tool by vacuum and overpressure. The injection from the resin takes place from the outside.

OEM/Vehicle Mercedes-Benz GmbH 2017 Mercedes AMG GT R System Supplier ACE Advanced Composite Engineering GmbH Material Processor    ACE Advanced Composite Engineering GmbH

Material Supplier Huntsman Resin Huntsman 8625 epoxy

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

Turbo Charger Outlet T-Joint

A 42% weight and 35% cost reduction, and improved airflow reducing the pressure drop (-8kPa) to increase fuel economy and improve NVH performance was achieved by designing and molding this part with plastic compared to the previous aluminum die cast part. Air flow noise was also reduced and long term durability increased via the rib pattern design. Special 3-gate positioning tooling was designed to minimize stress in weld-line area for strength and durability and for processing optimization. A new 35% glass fiber reinforced, heat stabilized polyamide 66 resin was developed for good retention of properties over time at temperatures up to 220 degrees C.

OEM/Vehicle Hyundai Motor Company 2018 Genesis G80, Kia Stinger System Supplier Hwaseung R&A Co., Ltd. Material Processor    Songwoo Industrial Seji Solotech, Inc.

Material Supplier DuPont Korea Inc. Resin PA66

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

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

Low Friction Polymer for Chain Tensioner Arms

This usage of a modified PA46 resin to enhance stiffness, on vehicles powered by a 5.0L V8 engine, was a drop- in replacement for PA66, for enhanced wear and friction performance. The resultant fuel economy savings (0.4%), from rotational torque reduction in the cam-shaft (0.5Nm), was equivalent to a 40lb weight reduction, and at 1/10th the cost. Annual environmental benefits include reductions in gas consumption by 12,000 Barrels and green-house gas emissions by 5,000 Tons. This innovation is highly translatable, to provide affordable fuel economy improvement, and will be utilized on more Ford vehicles, beginning in 2018. The total potential environmental impact of translations, at Ford, may be multiple times the values noted for the Mustang and F-150.

OEM/Vehicle Ford Motor Company 2017 Ford F150 / Mustang System Supplier Borg Warner

Material Supplier DSM Resin Stanyl HGR2 PA46(+PTFE)

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

Carbon Fiber Filled PP

Using recycled carbon fiber filled polypropylene, (changed from ASA) and changing soft material from TEA to TPE, creating a new material specifically for this "A" pillar bracket, resulted in a 14% weight reduction and $186,158 yearly cost save (300,256 volume). Significant CLTE reductions were also achieved. The rigid portion of the material is designed to fit existing tooling, and be compatible with the new soft material resulting in a new hard/soft material system for more cost effective carbon fiber based applications for exterior and interior trim parts. The carbon fiber is recycled from various sources including airplane bodies and bicycles.

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

Material Supplier Borealis Compounds Inc Resin Fibermod CB061SY PP

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

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