Drive -Axle Inspection-Cover Assembly

This rear-differential inspection cover for commercial trucks has been converted from a 7-piece aluminum and steel assembly to a 2-piece aromatic PA system that reduced weight >40% and cost 20%.  The resin was selected for its high strength, chemical compatibility, and creep resistance.  Developed in <20 weeks, the system has passed rigorous gravel bombardment, thermal cycling (spike and shock), dimensional integrity, and chemical resistance tests and also provides savings on warranty, freight, and serviceability, plus provides a quieter transmission without need for secondary parts or sound dampeners.

OEM/Vehicle AB Volvo 2007MY Mack 150 System Supplier American Axle Material Processor Sturgis Molded Products

Material Supplier Mitsubishi Engineering Plastics Corp. Resin Reny N252 MXDX6 Tooling/Equipment Supplier Sturgis Molded Products

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

Crash-Boxes for Truck-Cabin Occupant Protection

Injection-molded PC/PBT was used to form left and right side crash boxes that allowed the commercial truck OEM to meet the very high (30kJ) impact energy of this crash requirement in India.  The versatile design allows both left- and right-hand parts to be  molded from the same tool while reducing weight 30% vs. the previous steel system.

OEM/Vehicle Volvo-Eicher Commercial Vehicle Pvt Ltd. 2011 India 7T LCV commercial truck System Supplier Machino Plastics Ltd. Material Processor Machino Plastics Ltd.

Material Supplier SABIC Innovative Plastics Resin Xenoy 1102 PC-PBT Tooling/Equipment Supplier Machino Plastics Ltd.

For more Information See: http://www.plastics-car.com/Todays-Automobiles/Automotive-Safety

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