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

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

High Elongation Fabric

This high elongation PVC coated fabric is formulated and designed for wrapping tight radius parts with no texture lost or deformation. It is designed to support a variety of applications including seating, headrests, map pockets, consoles, doors and instrument panels. This high stretch material provides a leather like look and feel in any color, accommodates high strain without tearing making it easy to implement stitching applications, and meets sun load requirements. The estimated cost is $2 USD a sq. ft. less than leather.

OEM/Vehicle Ford Motor Company 2015 Ford MKC System Supplier International Automotive Components (IAC) Material Processor    International Automotive Components (IAC)

Material Supplier CGT Resin PVC Tooling/Equipment Supplier CGT

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

Grained Roof Ditch Moldings

Usually, a grain appearance in extruded parts is achieved via embossing rollers confining the look to the top surface of the part only. This unique PVC material development has the grain in the material enabling a grain appearance throughout the part, including the sides of the extrusion, without secondary operations required. This enables greater styling options for interior and exterior part designs at less cost. A 10% direct cost savings is associated with this innovation through process efficiency and lower equipment maintenance costs. Approximately $30K cost avoidance savings annually is directly associated with this innovation. it is scratch and mar resistant, weatherable, co-extrudable and it also bonds to metal.

OEM/Vehicle General Motors 2017 GMC Sierra, Chevrolet Silverado System Supplier Martinrea International Material Processor    Martinrea International

Material Supplier Teknor Apex Resin Apex 85 - J438N Black 621 PVC Tooling/Equipment Supplier Rollstar Metal Forming

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

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

Brake Light Lenses

Coating elimination, through the use of a standard colored polycarbonate (PC) with specialty copolymers, enabled a cost reduction of $0.80 per part and a program cost avoidance of $145,000 annually. The lenses are weatherable and directly recyclable. Coating elimination avoids VOC emissions and water use (cleaning the paint line) resulting in further environmental benefits.

OEM/Vehicle General Motors 2018 Chevrolet Onix System Supplier Olsa Material Processor    Olsa

Material Supplier SABIC Resin Lexan SLX 2271T PC Tooling/Equipment Supplier Olsa

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

Non-weakened Skin for Seamless Airbag System

This scoreless skin technology eliminates the visible line of the airbag door. A special bi-laminate foil with TPO chemistry for unique tensile, shear and processing characteristics enables an improved surface appearance over previous scored IP skin constructions. Parts are injection molded with inmold lamination. No high capital expenses ($750,000 cost avoidance) for laser score equipment make this doable globally in low cost, low tech countries. The previous process included injection molding the substrate, cutting and sewing and hand wrapping the top skin cover and laser scoring the composite panel. Streamlining the production results in a $1.5/part cost saving. Since the skin is not weakened by scoring, the underlying substrate can be made weaker to enhance the airbag deployment door opening time.

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

Material Supplier Haartz Resin Deploy Bilaminate TPO Tooling/Equipment Supplier GS Engineering

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

Squeak Resistant IP Cluster Bezel

This IP cluster was molded with a new, patented low gloss ABS resin that provides parts with a markedly lower coefficient of friction that eliminates squeak and “stick/slip” noises caused by interior components in a vehicle. 22 pieces of felt, 16 Mylar tapes and grease were eliminated in assembly resulting in cost savings of $1.62 per vehicle. There are 9 commercialized applications in North America resulting in $4 Million annual savings. This new material offers "no squeak" properties, drop in usage (replaces general purpose ABS without need for tooling modifications), high flow for larger more difficult to mold parts, and is not additive based. Low gloss appearance eliminates need for painting.

OEM/Vehicle Ford Motor Company 2016 Ford Mustang System Supplier Summit Polymers Material Processor Summit Polymers

Material Supplier Techno Polymer America Resin HUSHLLOY HS301 ABS

For More Information See: http://www.plastics-car.com/Automotive-Group/Sponsored-Projects-and-Industry-Issues

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

Grill Opening Reinforcement

This is the first Grill Opening Reinforcement with 100% Post Consumer Recycled Carpet Fiber Material. The material was a direct drop in with no tooling adjustments required. A 10% cost save was achieved using the recycled material compared to new material. The application recovered 536,667 yards (84 football fields) carpet. The GRO structurally ties the upper rails to the lower frame rails. It provides the general shape of the frontend and absorbs energy during a frontal impact. It also provides for a rigid mount for a crash sensor and facilitates attachment schemes for components such as head lights, hood latch and front fascia assembly.

OEM/Vehicle Ford Motor Company 2017 Lincoln MKC, Ford Fusion System Supplier Montaplast / Magna Material Processor    Montaplast / Magna

Material Supplier Wellman Advanced Materials Resin Ecolon GF3030 & GF1960 PA6

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

Low VOC and Odor Polyurethane Headliner

New low VOC and odor regulatory requirements in the Asia Pacific region were achieved on this polyurethane headliner, one of the largest interior trim parts. New materials - ISO and Polyol Process, general foam pouring and curing applications, and wet PU compression molding processing made this possible. Also, a special air ventilation system during foam curing and the slicing process was developed. Chemical additives were added into the wet PU processing to reduce VOC. This project initiated the commonization of raw materials for headliners across the AP region and has the potential for  optimization/globalization of a headliner bill of materials.

OEM/Vehicle Ford Motor Company 2018 Ford EcoSport, Fusion & Kuga System Supplier Grupo Antolin Material Processor    Grupo Antolin

Material Supplier BASF Corporation Resin 119M2 ISO/Poly 119M2 Tooling/Equipment Supplier Grupo Antolin

For More Information See: http://www.plastics-car.com/Automotive-Center/Member-Companies

Post Consumer Recycled PA66 for Window Support Bracket

For this application, 100% PCR (Post Consumer Recycled) PA66 resin replaced virgin PA66 and PP resins to provide high damping properties to reduce or eliminate squeak, rattle and window vibration. As damping properties are inherent in PA 66 resin, no new product development was required. As the same injection

molding process used to process the former resins as the new recycled material could be used, no new tooling was required either. This process can be translated to other applications further reducing landfill waste.

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

Material Supplier Ravago Resin Enviramid N1335HL, 30167 35% GFR, PCR, PA66

For More Information See: http://www.plastics-car.com/Automotive-Center/Fact-Sheet

Ultra Capacitor Barrier Shield

This application uses material recycled from tires and plastic caps to make TPE shields to protect the ultra capacitor from the hotter surrounding environment by deflecting heat away from it. This has prevented 5,000 tires and 25,000 lbs of plastics from landfills to date. Die cutting, thermoforming and vibration welding is used to produce this part for the first time, opposed to 2-shot injection molding, resulting in an $80,000 savings in tooling compared to tooling for steel or aluminum used previously. A 16 week same save is also achieved. Consumers benefit as the heat shields keep the battery cool preventing possible battery failure. This application can be translated to other exterior applications.

OEM/Vehicle General Motors 2018 Cadillac CTS System Supplier GDC Incorporated Material Processor    GDC Incorporated

Resin Enduraprene 2390/2195Re TPO Tooling/Equipment Supplier GDC Incorporated

For More Information See: http://www.plastics-car.com/Automotive-Center/Mission

Closed Loop Plastics & End-Of-Life Resin Use

Folding seat modules and plenum ducts are being produced with recovered 100% PCR PET resin from water bottles from CAMI Assembly Plant. The Lavergne Group Inc. has worked with GM CAMI Assembly Plant’s Global Environmental Compliance and Sustainability - Canada Region to implement the bottle collection program at the Lavergne facility. The recycled PET plastic is washed, flaked and turned into pelletized sustainable engineering resins. Bottle collection started in February 2017. This project is a demonstration of circular economy, bringing water bottles from CAMI, a landfill free, zero waste operation, processing them and returning those bottles in the form of a component to the same plant that generated the bottles.

OEM/Vehicle General Motors 2017 Chevrolet Equinox, GMC Terrain System Supplier Windsor Mold Group Material Processor    Windsor Mold Group

Material Supplier Lavergne Resin VYPET VNT 835 35% GFR, PCR, PET Tooling/Equipment Supplier Windsor Mold Group

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

Use of Soybean Oil in Slap Pad

This is the first use of soybean oil, to replace up to 40% of the 100% petroleum oil in the natural rubber part. It can be translated to any vehicle line with leaf springs including trucks, vans and SUVs. The current volume of petroleum oil being replaced in this application is approximately 522 gallons/year. This replacement of petroleum oil, with a natural resource, also offers a reduction in noise and an improvement in part durability. This will result in a reduction in warranty replacement of slap pads, estimated as a $2.5M warranty cost avoidance.

OEM/Vehicle Ford Motor Company 2018 Ford F150 System Supplier Rassini Material Processor    Rassini

For More Information See: http://www.plastics-car.com/Recycling/Life-Cycle-Assessment-Public-Policy-Development