WINNER

Chassis / Hardware - Entry 65

 

 

All-Plastic Window Regulator

 
OEM: DaimlerChrysler
Model: PT Cruiser
Model Year: 2006
System Supplier: DURA Automotive
Molder / Processor: Titan Plastics
Toolmaker: Titan Plastics
Material Supplier: Michael Day Enterprises
Generic Resin Type: PA 6/6
Resin Trade Name: Gearcomp
Grade: 6001
     
Summary:  This product is a lightweight highly efficient window regulator with all major components produced from plastic instead of steel. The simple design reduces part count over other conventional regulator designs. And the Racklift™ provides inboard/outboard flexibility that improves efficiency and reduces efforts and seal wear due to imperfect matching between the regulator and door glass path.

 

Finalist

Chassis / Hardware - Entry 24

   

 

Vacuum Brake Booster Valve Body

 
OEM: Mitsubishi
Model: Eclipse / Spyder
Model Year: 2006
System Supplier: Robert Bosch Corporation
Molder / Processor: Friedrichs & Rath GmbH
Toolmaker: Friedrichs & Rath GmbH
Material Supplier: DSM Engineering Plastic
Generic Resin Type: PET
Resin Trade Name: Anite
Grade: AV2-370/B
     
Summary:  The reaction disc cup is a molded feature on this part, which allows for the mating steel part to be made via a less-complex manufacturing process. This provides cost savings in addition to a 34% weight reduction. The part has direct interaction with 18 other components, including 7 different vacuum sealing locations (3 of which are dynamic), and incorporates long air-flow features for fast booster response.

 

Finalist

Chassis / Hardware - Entry 40

   

 

Glass-Run Retainer Assembly

 
OEM: Ford
Model: Mustang
Model Year: 2005
System Supplier: Cooper Standard Automotive
Molder / Processor: ELS Plastics Corporation
Toolmaker: Concours Mold Inc.
Material Supplier: BASF Corporation
Generic Resin Type: ASA
Resin Trade Name: Luran S
Grade: 778 T
     
Summary:  This traditionally multi-piece assembly is consolidated into one PIA that provides both glass and body sealing against water and noise intrusion. The component reduces weight 25-30% over separate inner / outer panels with metal-frame construction, while providing a 20% reduction in part and assembly costs. Better aesthetics are also achieved with no additional finishing.

 

Finalist

Chassis / Hardware - Entry 50

   

 

Active Vacuum Booster Connecting Plunger

 
OEM: DaimlerChrysler
Model: Durango
Model Year: 2006
System Supplier: Robert Bosch Corporation
Molder / Processor: NYX Fort Wayne
Toolmaker: NYX Fort Wayne
Material Supplier: Chevron Phillips Chemical Co. LP
Generic Resin Type: PPS
Resin Trade Name: Ryton
Grade: R4-200BK
     
Summary:  The active vacuum booster connecting plunger achieved a 79% weight reduction by replacing steel. Highly functional plastic design allows additional molded-in features while achieving a 5% cost reduction. The part must meet high load and wear-resistance requirements for life while maintaining tighter-than-industry-standard tolerances. 

 

 

Chassis / Hardware - Entry 22

   

 

Electric Parking Brake

 
OEM: Audi
Model: A6
Model Year: 2004
System Supplier: TRW
Molder / Processor: Oechsler
Toolmaker: Oechsler
Material Supplier: Ticona
Generic Resin Type: PPS
Resin Trade Name: Fortron
Grade: 1140L4
     
Summary:  The electric-parking brake (EPB) system replaces mechanical parking brakes and the bulky mechanisms associated with them (e.g. hand levers, foot pedals, cable mechanisms, etc.). It features drive-away assist for hill starts, and emergency braking via the vehicle stability-control system, providing more driver comfort and convenience.

 

Chassis / Hardware - Entry 23

 

Truck Tire Tray

 
OEM: Honda
Model: Ridgeline
Model Year: 2005
System Supplier: Ventra Plastics
Molder / Processor: Ventra Plastics
Toolmaker: Concours Mold Inc.
Material Supplier: Ticona
Generic Resin Type: GF PP
Resin Trade Name: Celstran
Grade: PP-GF30-03
 
Summary:  The use of long-fiber-reinforced thermoplastic (LFRT) polypropylene (PP) instead of thermoset sheet-molding compound (SMC) provides a unique balance of stiffness, strength, and toughness at both high and low temperature extremes, as well as a 30% cost improvement. The unique concealed-tray design provides additional trunk space with improved security, while a 30 - 35% weight savings improves fuel economy.

 

 

Chassis / Hardware - Entry 39

   

 

Power-Steering Reservoir Pump

 
OEM: Ford
Model: Focus
Model Year: 2006
System Supplier: Plastech
Molder / Processor: Plastech Port Huron
Toolmaker: Plastech
Material Supplier: Rhodia
Generic Resin Type: PA 66
Resin Trade Name: N/A
Grade: SSD330
     
Summary:  First considered to be “non-manufacturable," this power-steering reservoir has been relocated away from the exhaust while using fewer hydraulic-line connections, requiring 35% less power-steering oil, and reducing warranty costs. Interior noise has also been reduced, a 1.5 lb / vehicle weight savings achieved, and there is a cost savings of $10.33 / vehicle.

 

 

Chassis / Hardware - Entry 45

   

 

Door Module

 
OEM: General Motors
Model: GMT201
Model Year: 2005
System Supplier: Delphi Corporation
Molder / Processor: Delphi Corporation
Toolmaker: M2M / Synergetic Group
Material Supplier: Adell Plastics
Generic Resin Type: 40% GF PP
Resin Trade Name: N/A
Grade: ER-38 BK
     
Summary:  With this door hardware module, higher cost, higher mass, glass-filled polycarbonate / polyethylene terephthalate (PC / PET) resin has been replaced by glass-filled polypropylene (GF PP). This particular grade of resin was developed to meet the application's requirements for high dimensional stability; high-temperature strength, creep, and fatigue properties; and grease resistance, while performing at lower cost and mass. Additionally, the material is recyclable, allowing for reuse of process scrap in the product and facilitating end-of-life recyclability.

 

 

Chassis / Hardware - Entry 59

   

 

Engine Acoustic Belly Pan

 
OEM: DaimlerChrysler
Model: Jeep Liberty
Model Year: 2005
System Supplier: BBi Enterprises
Molder / Processor: BBi/Jinyi Automotive
Toolmaker: BBi/Jinyi Automotive
Material Supplier: China Petrochemical
Generic Resin Type: HDPE
Resin Trade Name: N/A
Grade: 6070EA
     
Summary:  This application combines a noise-containment system with a molded plastic part. The requirements for developing a noise-containment device were complicated by lack of space between the engine, the front engine cradle, and the front skid plate. Containment and retention were managed despite all of these packaging challenges. The plastic part retains the noise-containment devices and conforms to the top side of the skid-plate package.