Gen-3 4-way Head Restraint

This low cost, low mass, head restraint provides exceptional rigidity for whiplash protection. Its flexible design allows the front surface of the head restraint to be translated closer to or further from the occupant by 60 mm without incurred costs (allowing for the precise balancing of comfort and safety). Using plastic, in place of steel, as the primary load bearing component is new to front row head restraints. The part design eliminates manufacturing complexity making use of intelligent geometries so that readily available materials could be used. A $10.73 Million savings ($2.80/vehicle) is projected by the end of MY2020.

OEM/Vehicle Ford Motor Company 2018 Ford F150 System Supplier Windsor Machine and Stamping Material Processor    Windsor Machine and Stamping

Material Supplier Ravago Resin Hylon N1000STHL PA Tooling/Equipment Supplier Integrity Tool & Mold

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

Two Shot Interior Decoration Bezel

This unique 3-D decorative effect was achieved with 2K 'reverse' injection molding (1st shot tinted PC) with overmolding of grained surface with 2nd shot (self colored pigmented ABS). This is the first time this process was used to achieve the 3-D visual effect (color and texture) for a part of this size and geometry. A 30% cost save was achieved vs IMD/IML/high gloss painting and there was a 20% scrap reduction vs conventional 2-layer high gloss piano black appearance.

OEM/Vehicle Ford Motor Company 2018 Ford Fiesta System Supplier Faurecia Interior Systems Material Processor    Faurecia Interior Systems

Material Supplier Lotte Advanced Materials Resin INFINO LT1220 PC Starex LX0760 ABS Tooling/Equipment Supplier JP Grosfilley SAS

For More Information See: http://www.plastics-car.com/Todays-Automobiles/Latest-Trends?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

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

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

Powertrain Mounting Clevis Bracket

This engine clevis bracket is the first composite mount designed for a 6 cylinder engine, and passing peak loads of 25 Kilo-newtons of force. The injection molded part replaces metallic solutions (stamping, welding and die-casting) used previously resulting in a 45% weight save. NVH was also improved (reduction in cabin noise) due to the damping characteristics of the polyamide compared to aluminum. Corrosion resistance is improved and the part can be recycled at end of life. Seven clevis brackets were developed for different powertrain combinations and there are no warranty claims after 1.5 years of production

OEM/Vehicle General Motors 2017 Cadillac XT5 System Supplier Hutchinson

Material Supplier BASF Corporation Resin Ultramid A3WG10 CR BK00564 PA66+50%GF

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

Instrument Panel Carrier

Long glass fiber PP injection molding via structural chemical foaming with core-back process enabled the production of this part with very low VOC emissions, meeting VDA 278 specification. Extensive CAE work predicting warpage of the foamed part provided valuable insights, allowing for the modification of tooling in advance. Use of foaming means less material is required resulting in a 15% weight savings, fewer emissions and less cost.

OEM/Vehicle BMW 2017 Countryman System Supplier International Automotive Components (IAC) Material Processor    International Automotive Components (IAC)

Material Supplier SABIC Resin Stamax PP LGF Tooling/Equipment Supplier Siebenwurst

For More Information See: http://www.plastics-car.com/Partners/Colleges-and-Universities

Structural AGS w/Integrated Loose Layer Construction

This, possibly the largest 2-shot AGS in production today, was designed with an integrated locating and attaching system for consistent fit between the grille and headlamps eliminating the need for FEM assembly, dunnage and shipping. Savings are estimated at $5 per part system, additional $16 inside cost in addition to $45 markup and shipping, $1 in labor by eliminating 4 fasteners, and inplant tooling avoidance of $2 Million for a new cell and assembly tooling. A 1 lb weight savings was achieved, plus an additional 3 lb avoidance over a metal/plastic hybrid assembly.

OEM/Vehicle Ford Motor Company 2018 Ford Expedition System Supplier Magna Plastcoat Material Processor    Magna Plastcoat

Material Supplier Celanese Resin Celstran 40-20 PP/GF Tooling/Equipment Supplier Integrity Tool

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

Integrated Floor Bedliner Divider

This first time twin sheet thermoformed bedliner divider is integrated into the bedliner as one piece. A $275 cost avoidance resulted by not having to manufacture a separate floor divider part. The divider incorporates a molded in locking feature to secure the divider into the truck wall when it is raised. It eliminates the need for a cargo net or separate divider allowing the customer to put smaller items in the bed without having the items move and slide around while the vehicle is in motion. Dual textures are achieved on both sides of the part and the design can be applied to different vehicle models and brands via an insert for different logos.

OEM/Vehicle General Motors 2017 Chevrolet Silverado System Supplier Penda Corp. Material Processor    Penda/Durakon

Material Supplier A. Schulman Resin Polytrope TPP1026EU TPO Tooling/Equipment Supplier Penda Corp.

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

Seat Cushion Frame and Storage Door

For the first time, a polymer composite has replaced magnesium in a structural seat-cushion frame and under-seat storage lid for a front center 20% seat with integrated restraint system. The application is weight neutral and lower cost (≈$4 USD/unit), and satisfies all safety and crashworthiness requirements. Its flexible architecture allows for updates with future enhancements. Injection molded 40% LFT-PP is used to mold the frame, which also features an EPP antisubmarine foam block and a lockable ergo-latch. The assembly represents a significant reduction in carbon footprint vs. magnesium and has yielded 2 awarded and 2 pending patents.

OEM/Vehicle Ford Motor Co. 2016 Ford Super Duty System Supplier Royal Technologies Corp. Material Processor    Royal Technologies Corp.

Material Supplier Celanese Corp. Resin Celstran PP-GF40-20 Tooling/Equipment Supplier Vortec Tooling Solutions, Inc.

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

Robotic Laser Cutting & Welding of TPO Fascia

A hydraulic punch and sonic welding operation was replaced by robotic laser cutting and welding of a Class A exterior fascia. Unlike other welding processes, it is not necessary to thicken wallstock in weld areas to prevent read-through with robotic laser welding of brackets on the backside of the part, and that reduces weight slightly. It also eliminates the need for contoured horns and punches. Clean cuts can be made in 1 sec on the painted side of the part. The dual-function process provides greater flexibility between programs and reduces floor space and tooling costs.

OEM/Vehicle General Motors Co. 2017 Chevrolet Camaro ZL1 System Supplier Magna Exteriors, Inc. Material Processor    Magna Exteriors, Inc. - DexSys

Material Supplier LyondellBasell Resin Hifax TYC1168X TPO Tooling/Equipment Supplier Jenoptik AG

For More Information See: http://www.plastics-car.com/Recycling-of-End-of-Life-Vehicles

Air Intake Manifold

This is the first air-intake manifold launched in China using 35% GR-PP to replace PA 6/6. The application provides 25-30% cost reduction and 15-20% molded-part weight reduction while retaining properties at high temperatures and improving weld strength, and NVH by 5 dB. Unique technology involving finer glass fibers and special sizing helps meet performance requirements. Parts are vibration welded.

OEM/Vehicle Volkswagen AG 2015 EA21 Engine  1.6L engines System Supplier Hua Tao Ltd Material Processor    Hua Tao Ltd

Material Supplier SABIC Resin SABIC G3135X PP

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

Vacuum Brake Tubes

A high-performance thermoplastic was needed for vacuum brake tubing to replace reinforced rubber. It needed broad temperature performance (-40-150C), chemical resistance, burst strength to 60 bar min. and flexural strength to 50 N min. It also had to resist vacuum collapse after 2 hr @ 150C and provide impact retention after 336 hr @ 150C. The design was changed to use a smaller diameter, thinner wall to simplify engine/undercarriage routing and eliminate heat shields plus allow quick connects. A TPC-ET elastomer with high thermal oxidative stability was developed. It is 30% lighter, less costly, and eliminates brackets.

OEM/Vehicle General Motors Co. 2016 Chevrolet Silverado & GMC Sierra System Supplier Cooper Standard Material Processor    Cooper Standard

Material Supplier DSM Engineering Plastics Resin Arnitel CM622 TPE

For More Information See: http://www.plastics-car.com/FAQs/Careers-in-Plastics.html?css=print

Closed-Loop Recycling of Bottles

This innovative, multi-stakeholder, cost-neutral recycling project protects the environment, grows local economies, creates jobs, and helps people in a sustainable manner. Water bottles collected at GM operations and from the Flint, Michigan area are directed into a supply chain that recycles the material into nonwoven fleece for specific applications including engine manifold cover insulation, insulation for coats that convert to sleeping bags for the homeless and are made by formerly homeless women as part of a jobs program, and air filters that purify the air at numerous GM and other manufacturing operations. Already 3.5-million water bottles have been repurposed.

OEM/Vehicle General Motors Co. 2016 Chevrolet Equinox, GMC Terrain System Supplier Exo-S Material Processor    Rogers Foam Co.

Material Supplier Wm. T. Burnett & Co. / Palmetto Synthetics LLC Resin Polyester

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

Strut Mount

This is the first use of a glass-reinforced PA material for strut-mount housings on all 4 corners of a vehicle and the first application of polyamide housings on the front and rear suspension systems. The injection molded parts integrate common components for both front and rear mounts, and employ a special thread assembly method with a locking feature.  They reduce mass 30% vs. typical steel and aluminum parts and reduce noise transmission through the suspension system. Thanks to modular assembly, the design also offers greater tuning flexibility.

OEM/Vehicle General Motors Co. 2016 Cadillac CT6 System Supplier ContiTech North America, Inc. Material Processor    ContiTech North America, Inc.

Material Supplier BASF Corp. Resin Ultramid A3WG10CR PA66 GF 50

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