WINNER

Materials - Entry 15

 

 

Molded-in-Color Reactor TPO for Airbag Covers

 
OEM: General Motors
Model: Buick Lucerne
Model Year: 2006
System Supplier: Autoliv
Molder / Processor: Key Plastics
Toolmaker: Key Plastics
Material Supplier: Basell Polyolefins
Generic Resin Type: TPO
Resin Trade Name: Hostacom
Grade: CA199P
     
Summary:  This new material is the first molded-in-color (MIC) reactor TPO with excellent cold-temperature impact resistance for Class-A side-airbag covers. The new TPO meets all related OEM specifications and offers significant cost savings vs. conventional painted covers.

 

Finalist

Materials - Entry 14

 

 

PC-Si Copolymer For Active Airbag Upper

 
OEM: General Motors
Model: Cadillac DTS
Model Year: 2006
System Supplier: Lear Corporation
Molder / Processor: Lear Corporation
Toolmaker: Hi-Tech Mold
Material Supplier: GE Advanced Materials
Generic Resin Type: PC-Si Copolymer
Resin Trade Name: Lexan
Grade: EXL1414H
     
Summary:  A new PC-silicone copolymer was developed to provide extreme low-temperature ductility, which enables robust performance in rigid passenger airbag panels at -30oC. The material's combination of rigidity, heat resistance, and low-temperature performance provides cost reductions in passenger airbag (PAB) systems through the elimination of additional strengthening components.

 

Finalist

Materials - Entry 36

 

 

Cross-Linked Expanded Polyethylene Seat Halo

 
OEM: General Motors
Model: Chevrolet Impala
Model Year: 2006
System Supplier: Lear Corporation
Molder / Processor: JSP International
Toolmaker: Schraml Metalworks
Material Supplier: JSP International
Generic Resin Type: xEPE
Resin Trade Name: Arpex
Grade: 4500 Series
     
Summary:  The seat halo is the comfort ring that surrounds the rear seat area and incorporates the headrest and bolsters as one complete part. Conventional materials such as PU foam typically require a wire for support, which is not required with xEPE. The xEPE material is soft, ductile, and reduces weight when compared to incumbent material systems.

 

Finalist

Materials - Entry 57

 

 

PP/PS/Nano Material for Heater Vent

 
OEM: Audi
Model: A3
Model Year: 2005
System Supplier: Dr. Haubitz
Molder / Processor: Dr. Haubitz
Toolmaker: N/A
Material Supplier: Putsch GmbH
Generic Resin Type: PP/PS
Resin Trade Name: Elan
Grade: XP
     
Summary:  This new material -- comprised of PP/PS and nanocomposite filler -- offers exceptionally low gloss (matte finish), very-good scratch resistance, and a mold shrinkage of less than 1%. This resin can replace painted interior styrenic materials at a 50% cost savings. Besides an aesthetically pleasing matte finish, this resin also offers a good surface feel, which is required for many interior parts.

 

Materials - Entry 13

 

 

Lightweight Carbon-Fiber Rear Deck Assembly

 
OEM: Ford
Model: GT
Model Year: 2005
System Supplier: Mayflower Vehicle Systems
Molder / Processor: Sparta
Toolmaker: Coast Composites Inc.
Material Supplier: Toray Composites (America), Inc.
Generic Resin Type: Epoxy
Resin Trade Name: G83C 
Grade: Torayca T600SC-24K
   
Summary:  The ultra-lightweight epoxy / carbon-fiber rear deck assembly significantly reduces weight vs. traditional metal systems. By adhesively bonding the carbon fiber / aluminum assembly, the galvanic-corrosion potential at attachment points is eliminated. Weight savings are in the range of 50 - 75% when compared to all-metal systems.

 

 

Materials - Entry 16

 

 

Molded-in-Color Metallic Shifter Knob

 
OEM: Ford
Model: F-150
Model Year: 2005
System Supplier: Dura Automotive
Molder / Processor: Wright Plastics
Toolmaker: Mold Tooling Systems
Material Supplier: GE Advanced Materials
Generic Resin Type: ASA/PC
Resin Trade Name: Geloy
Grade: FXW751SK
     
Summary:  This molded-in-color (MIC, metallic-appearance shifter knob eliminated the need for paint, saving more than $1 / vehicle. The knob is made of a new MIC, UV-stabilized, acrylonitrile styrene acrylate (ASA) / polycarbonate (PC) grade with metallic flake.

 

 

Materials - Entry 52

 

 

Carbon-Fiber Wheelhouse Assembly

 
OEM: General Motors
Model: Z06 Corvette
Model Year: 2006
System Supplier: Molded Fiber Glass
Molder / Processor: Premier Molding Company
Toolmaker: Penco Tool
Material Supplier: MFG Research
Generic Resin Type: Unsaturated Polyester
Resin Trade Name: Ashland
Grade: N/A
     
Summary:  This wheelhouse assembly uses a low-density carbon-fiber / unsaturated polyester material that saved over 25% in weight vs. metal assemblies. The carbon-fiber prepreg was formulated to run on standard compression tooling at normal production rates.