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Materials - Entry 19

WINNER

Two-Shot Load Bearing Touch-Off Molding
2005 Ford Mustang
System Supplier: Cooper Standard Automotive
Molder: Innatech
Tooling Supplier: Dynamic Mold
Material Supplier: A. Schulman/Zeon Chemicals
Resin:  Schulamid/Zeotherm PA 66/6 GF33H-31/100-80B GF PA 6/6 TPV
This is the first time an all plastic component has been used as a load bearing touch-off molding on a convertible. This is a multi-shot application of glass filled polyamide and new TPV resin that is chemically bondable to the polyamide. The design also incorporates an innovative clip attachment to vehicle.

 

Materials - Entry 9

Finalist

Static Dissipative Non-Slip Truck Bedliner
2005 Ford Pick-up Trucks
System Supplier: Durakon Industries
Molder: -
Tooling Supplier: -
Material Supplier: Solvay Engineered Polymers, Inc. 
Resin:  PE
This multi-layer laminate truck bedliner incorporates static dissipative and non-slip properties for reduced likelihood of hydrocarbon explosion and improved load management.

 

Materials - Entry 16

Finalist

3.7L V-6 Engine Valve Cover
2005 DaimlerChrysler 3.7L V-6 engine
System Supplier: Dana Sealing Products Division
Molder: Dana Sealing Products Division
Tooling Supplier: Shaw
Material Supplier: Premix
Resin: Premi-glass 1266 SMC
The 3.7L valve cover utilizes new polyester/vinylester thermoset hybrid resin. This material offers similar performance as a vinylester resin at a reduced cost. Application saved over 4 lbs per vehicle (versus steel) and was a 13% cost savings. Program was launched in record time (8-1/2 months).

 

Materials - Entry 14
Ceramic Matrix Composite Clutch Plate
2005 Dr. Ing.h.c.F.Porsche AG Carrera GT
System Supplier: Sachs Race Engineering
Molder: SGL Carbon
Tooling Supplier: -
Material Supplier: SGL Carbon
Resin:  Phenol
A new ceramic matrix, carbon fiber reinforced material has been developed for use in clutch plates. The extreme heat and wear resistance of the new high strength material allows the construction of clutches with minimum diameter for road going cars. It combines race clutch technology with the durability of conventional car clutches. The use of woven carbon allows up to 20,000 RPM service due to the extremely high specific thermal stress resistance. 

 

Materials - Entry 22
Low Gloss PA/ABS Resin for Mirror Housings
2004 General Motors All Vehicles with On-Star
System Supplier: Magna Donnelly
Molder: Adkey, Inc.
Tooling Supplier: -
Material Supplier: BASF
Resin:  Terblend N NM-19 ABS/PA6
This new PA/ABS resin achieves a low gloss and high quality matte finish without the use of paint. Terblend N PA/ABS is less dense than comparable materials, allowing for weight savings. The resin is also a high-flow material, so it is easy to mold in complex tools, and requires minimal adjustments for tooling and process conversions.

 

Materials - Entry 56
High Strength, Low Density SMC
1996 General Motors Corvette, Cadillac XLR, Buick LeSabre, Pontiac Bonneville
System Supplier: Meridian, Budd Company
Molder: -
Tooling Supplier: -
Material Supplier: -
Resin:  SMC
Using a novel combination of thermoplastic and thermoset resins, a family of composite materials that gives a 30% mass reduction over conventional SMC has been developed. Some examples of the current applications are the inner panels of the Corvette and Cadillac XLR as well as the front-end support panels of Buick LeSabre and Pontiac Bonneville.