Several Thermoplastic 'Firsts' Among 2018 SPE Automotive Awards

Spanning nine categories, including one newly added for Additive Manufacturing, the Society of Plastics Engineers Automotive Division’s 2018 Blue Ribbon Automotive Innovation Awards (which this editor helped judge) represented a number of “firsts” in either metal replacement or replacement of earlier plastics solutions with better options. In this 48^th annual competition, the oldest and largest competition of its kind globally, thermoplastics and/or thermoplastic composites ruled. Here’s a look at the winners, starting with the grand winner award—also the winner of the Powertrain category.

POWERTRAIN: VACUUM GENERATION SYSTEM FOR BRAKE ASSIST

The open/close valve-actuation system made its debut in the 2017 Ford F-150 pickup, and was designed and supplied by Tier One supplier Dayco Products and molded by MacLean-Fogg’s Engineered Plastics unit. The system utilizes two complimentary resin systems from DuPont Automotive—Delrin 73M30 acetal with PTFE, and Minion 520MP mineral-filled nylon 6—which together prevent “stick-slip” and result in no measurable wear after 2.5 million hot/cold test cycles. A 40% weight savings and a 25% cost savings over current pump systems was achieved.

This application is transferrable to other Ford platforms and is being considered by other car companies.

ADDITIVE MANUFACTURING: WINDOW ALIGNMENT FIXTURE

This fixture appears in the 2017 Ford Mustang convertible and was produced by Stratasys using its Fused Deposition Modeling (FDM) system and nylon 12 with 35% short carbon fiber. The fixture integrates pneumatic control, eyelets for a stowage rack, trigger-switch housing, ergonomic handles, gauge-protector deflector and pneumatic-tubing retainers and switch mounts. This unit is 30% lighter and cheaper to produce than a traditional welded fixture. It is also much faster to manufacture—taking only 50 hr to build the integrated fixture with handles and mounting brackets.  Moreover, ergonomics reportedly were improved significantly. The plastic fixture allows for easier handling and avoided the requirement for a lift assist.

BODY EXTERIOR: THERMOPLASTIC LIFTGATE

This liftgate appears in the 2019 Fiat Chrysler’s Jeep Cherokee SUV, and was molded by Magna International’s Magna Exteriors business. It’s injection molded from Trinseo’s DLGF 9411, a 40% long-glass PP with good flow properties, and Lyondell Basell’s Hifax TYC, a very high-flow TPO containing 30% glass. The integrated tethering attachments are molded in glass-filled nylon. Replacing a steel liftgate with a thermoplastic design enabled a 28% weight reduction and a 50% savings in tooling and capital investment through part integration and manufacturing efficiency.

An industry-first use of conformal infrared welding behind the MIC (molded-in-color) grain class A surface increased structural and dimensional performance and enabled quicker processing.  Bonded brackets enabled novel tethering attachments without fasteners, improved metal reinforcement efficiency, and maintained styling surface wrap in D pillars without sacrificing DLO. All this was accomplished within an 18-month window.

BODY INTERIOR: INTEGRATED MODULAR PELVIC BOLSTER

This application appears on the 2018 Ford Lincoln Navigator SUV and is  molded by Faurecia Interior Systems from LyondellBasell’s Profax SX702, a high-flow, high-impact PP copolymer. The unit combines two unique side-impact bolster designs. Integrating them into the map packet resulted in tooling cost savings estimated at $100,000. There was an additional $100,000 indirect savings in testing time and $8 per vehicle cost avoidance vs. using add-on bolsters. An approximate 10% weight savings was achieved.

CHASSIS/HARDWARE: HIGH-STRENGTH, SELF-TAPPING COMPOSITE NUT

This appears on the 2016 Fiat Crysler Pacifica minivan and is molded by ITW Deltar Fasteners from Asahi Kasei Plastics’ Leona 90G55, a 55% glass-filled nylon 66. This composite nut has self-healing properties, enabling it to maintain sufficient torque and clamp load even after it has been stripped, unlike the metal nut that it replaces.

Total mass savings is 8 g per location x 121 locations, for a total vehicle mass savings of 2.1 lb for this vehicle. Estimated cost savings per vehicle is $3.25. The composite nut can be translated across all OEMs and in many additional applications.