Intake Manifold with 2-Shot Molded Power Valve

This air intake manifold blade was made via a 2-shot molding process overmolding a thermoplastic polyester elastomer over a 36% mineral filled nylon 66. in the same tool. The previous process required two suppliers - one to injection mold the nylon portion of the blade and another to compression mold a rubber-FKM surround requiring additional assembly. This new process resulted in a 33% direct part savings and additional freight and transit savings using one location to manufacture the part in place of three

OEM/Vehicle FCA US LLC 2017 Dodge RAM System Supplier MAHLE Filter Systems Material Processor    MAHLE Filter Systems

Material Supplier Dupont Automotive Resin Hytrel 3078 HS BKB320 TPC-ET Tooling/Equipment Supplier MGS Mfg. Group

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

Overmolded Chain Snubber with Integral Baffle

This application represents the first time that chain-noise reduction (snubbing) and fluid-sealing functions have been integrated into a single compact component with 2 thermoplastic materials for a soft/hard combination. It also is the first time that a snubber has been used on the coast side of the sprockets, and the first time "stitching features" have been used to mechanically attach 2 materials in little space to meet packaging constraints. The PA 4/6 material was selected for its outstanding wear resistance. The final component was 31% lighter than the previous system, while meeting stringent noise requirements of the EV.

OEM/Vehicle General Motors Co. 2016 Chevrolet Volt System Supplier GM Powertrain Material Processor Parker Hannifin Chomerics Div.

Material Supplier DSM Engineering Plastics DuPont Automotive Resin Stanyl TW341 PA46 Hytrel 7246 TPC-ET Tooling/Equipment Supplier Advanced Tool & Mold Inc.

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

Thermoplastic CV/J Boot Seal

The first global implementation of a blow-molded, thermoplastic elastomer (TPE) constant velocity joint (CVJ) half-shaft drive-axle boot seal used on 1984 MY E/K platform produced by then General Motors Corp. (was selected as the 2014 Hall of Fame winner. This application was a far more robust CVJ sealing solution that also was lighter, more durable, and less costly than the injection-molded rubber boots it replaced. It has been in continuous use on GM cars and trucks for 30 years, and 85% of front-axle CVJ boot seals on light-duty vehicles worldwide now use TPE in this application.

OEM/Vehicle General Motors Co. 1984 E/K Platform System Supplier Nexteer Automotive Material Processor ABC Group Inc.

Material Supplier DuPont Automotive Resin Hytrel TPC-EC

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

TPE Jounce Bumper

This is the first TPE jounce bumper that integrates several components into a single part to help deliver lower systems costs and better performance, including improved durability, noise, and mechanicals under demanding conditions such as low temperatures, high humidity, or high loads.  The use of an injection / blow molded TPE to replace injected foam polyurethane eliminates the need for metal or PA saturation cups due to better saturation height control, which in turn allows total suspension height to be reduced.  Additionally, 10% mass savings, shorter processing cycles, and lower systems costs were achieved.

OEM/Vehicle Fiat Chrysler Automobiles 2015 Fiat Punto supermini car System Supplier Insit Material Processor Insit

Material Supplier DuPont Automotive Resin Hytrel HTR8724 TPC-ET

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

Integrated Transmission Baffle / Seal Lip

This is the first-ever single-materal design for an integrated transmission baffle/lip seal.  The GM patent-pending design eliminates oil aeration for improved clutch durability to 200,000 miles, provides 50% increase in oil life, improves pump performance 45%, and offers easier assembly and provides smoother shift performance.

OEM/Vehicle 2008 Chevrolet® Malibu® / GM Daewoo® Tosca® / Buick ® LaCrosse® China sedans by General Motors System Supplier Chunil Engineering Material Processor Chunil Engineering

Material Supplier DuPont Automotive Resin Hytrel ® 7246 TPC/ET Tooling/Equipment Supplier Chunil Engineering

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