Archive Page 2

31
Oct
16

Dr. Uday Vaidya Named SPE® Composites Person of the Year

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The board of directors for the SPE® Composites Division have named Dr. Uday Vaidya, University of Tennessee/Oak Ridge National Laboratory (UT/ORNL) governor’s chair in Advanced Composites Manufacturing and professor in the Department of Mechanical, Aerospace & Biomedical Engineering (MABE) at University of Tennessee-Knoxville (UTK) as well as chief technology officer for the Institute for Advanced Composites Manufacturing Innovation (IACMI) as the recipient of the group’s 2015-2016 Composites Person of the Year award. Vaidya was recognized at a special ceremony during the 2016 SPE Automotive Composites Conference & Exhibition (ACCE), September 7-9 in Novi, Mich. in the Detroit suburbs.

 

First given in fiscal year 2004-2005, the Composites Person of the Year award publicly acknowledges a contributor who has provided significant aid to the SPE Composites Division, particularly during the prior year, as well as made broader contributions to the composites industry as a whole. Nominations are reviewed by the board and one recipient is selected by the current division chair in consultation with the current division awards chair.  Previous winners of the award and their employers at the time include:

 

  • 2004-2005: Dan Buckley, American GFM,
  • 2005-2006: John Muzzy, Georgia Institute of Technology,
  • 2006-2007: Jim Griffing, The Boeing Co.,
  • 2007-2008: Fred Deans, Allied Composite Technologies LLC,
  • 2008-2009: Peggy Malnati, Malnati & Associates LLC,
  • 2009-2010: Dale Grove, US Silica,
  • 2010-2011: Dale Brosius, Quickstep Composites LLC,
  • 2011-2012: Creig Bowland, PPG Industries,
  • 2012-2013: Michael Connolly, Huntsman Polyurethanes,
  • 2013-2014: Jim Griffing, The Boeing Co., and
  • 2014-2015: Dan Buckley, American GFM (Lifetime Achievement).

 

uday_headshotExplaining why he selected Vaidya, Dr. Michael Connolly, SPE Composites Division chair and program manager-urethane composites at Huntsman Polyurethanes said, “Uday was chosen for his long-time contributions to the SPE Composites Division, including nine years of leadership on the education committee and eight years organizing the SPE ACCE student poster competition. Last year he created a new program under the education committee that helps universities apply for funding from the Composites Division — with university matching funds — to purchase teaching materials and laboratory equipment. In addition to these contributions, his effort fostering student development by organizing and advising a new SPE student chapter at University of Tennessee-Knoxville benefits all of SPE as well as the plastics and composites industries. And last, but certainly not least, we wanted to recognize his considerable contributions to the composites industry, including numerous patents, publications — including two books — and presentations at SPE  and other industry meetings, industry training workshops, and efforts writing SPE education grants for universities. He has a passion for engineering education and has mentored hundreds of young engineers who’ve now made their way into our industry, including over 60 Master’s and doctoral students.”

 

In addition to his academic responsibilities, in his current role at IACMI, Dr. Uday Kumar Vaidya chairs the technical advisory board, oversees technology roadmapping efforts, and helps shape high-value industry-led projects for the institute. Since joining UTK, he also has led the establishment of the 10,000-ft2/929-m2 Fibers and Composites Manufacturing Facility (FCMF) to serve IACMI and the Tennessee Manufacturing Ecosystem.

 

Prior to joining UT/ORNL, Vaidya served as department chair for Materials Science & Engineering and as center director for the Composites Center at University of Alabama at Birmingham (UAB). He also helped establish and then, as director, led the Materials Processing & Applications Development (MPAD) center at UAB, which focused on leading-edge manufacturing and commercialization of engineered plastics, polymers, fibers, composites, and metal castings.

 

During his career, he has contributed extensively to research and development of engineered polymers, fibers, and composites and has experience with a broad range of composites for defense, transportation, and industrial applications. Additionally, he has served as principal investigator (PI) or co-investigator (Co-I) on more than 100 projects worth over $22 million USD to date.

 

Vaidya has 29 years’ teaching experience at five academic institutions (UTK, UAB, North Dakota State University, Tuskegee University, and Auburn University) where he has developed and taught a variety of engineering courses to students from freshmen to graduate levels, and has been recognized with a variety of prestigious teaching awards, including Outstanding Faculty Member Award for the College of Engineering at UTK (2016), the Presidential Teaching Award for Excellence at UAB (2005 and 2013) and also UAB’s Graduate Dean’s Excellence in Mentorship Award (2014). In 2001, he received the Outstanding Teacher of the Year award at North Dakota State University’s School of Engineering, and received the Outstanding Faculty Award for Research in 1996 at Tuskegee University.

 

A prolific writer, Vaidya has been published in over 180 peer-reviewed international journals and over 350 conference proceedings.  He has contributed four book chapters, is the author of Composites for Automotive, Truck and Mass Transit, a book published by DesTech Publishers, and he is completing a second book on Composites for High Schools, Community Colleges, Hobbyists and Freshmen Engineering Students. He also contributes extensively to organizations and events such as SPE, CAMX (the Composites & Advanced Materials Expo), SAMPE (Society for the Advancement of Materials & Process Engineering), the ACMA (American Composites Manufacturers Association) and ICCM International (the International Conference on Composite Materials) as a session organizer, panel discussion coordinator, presenter, exhibitor, invited speaker, and think-tank discussion participant. Furthermore, Vaidya has organized several conferences and workshops himself dealing with composites and plastics research and education. His contributions were recognized in the August/September 2012 issue of CM (Composites Manufacturing) magazine as a B.E.S.T. (a bright, energetic, skilled trailblazer) from across the composites industry.

 

An entrepreneur as well, Vaidya is a principal and co-founder of Innovative Composite Solutions (ICS), an Alabama company that was established in 2009 after winning first place and $100,000 USD in the Alabama Launchpad Competition that year.  ICS has commercial ventures with high-tech, lightweight composite products for the infrastructure/buildings, power transmission, defense, biomedical devices, and commodity markets. Vaidya also has served as consultant for a number of companies producing fiber-reinforced plastic piping, power/energy, and plastic products.

 

He holds a B.S. degree in Mechanical Engineering from Karnataka University in India where he was first in his graduating class. He earned an M.S. degree in Mechanical Design Engineering at Walchand College of Engineering (also in India) and received a doctorate in Mechanical Engineering at Auburn University in the U.S.

 

About the SPE ACCE

 

Held annually in suburban Detroit, the ACCE draws over 1,000 speakers, exhibitors, sponsors, and attendees and provides an environment dedicated solely to discussion and networking about advances in transportation composites.  Its global appeal is evident in the diversity of exhibitors, speakers, and attendees who come to the conference from Europe, the Middle East, Africa, and Asia / Pacific as well as North America.  Fully one-third of attendees indicate they work for automotive and light truck, agriculture, truck & bus, or aviation OEMs, and another 25% represent tier suppliers.  Attendees also work for composite materials, processing equipment, additives, or reinforcement suppliers; trade associations, consultants, university and government labs; media; and investment bankers.  The show has been jointly sponsored by the SPE Automotive and Composites Divisions since 2001.

 

The 17th-annual SPE ACCE will be held September 6-8, 2017 at The Diamond Banquet & Conference Center at the Suburban Collection Showplace, 46100 Grand River Avenue, Novi, MI 48374.  For more information about the SPE ACCE, see http://speautomotive.com/comp.htm, or http://specomposites.com.

 

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® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.

30
Oct
16

Safety Category Finalists Announced for 2016 #SPEInnovationAwards Competition

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The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Safety Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: SAFETY

Seat Cushion Frame and Storage Door

OEM Make & Model: 2016 Ford Motor Co. Ford Super Duty pickup

Tier Supplier/Processor: Royal Technologies Corp.

Material Supplier / Toolmaker: Celanese Corp. / Vortec Tooling Solutions, Inc.

Material / Process:  Celstran GF40-20 LFT-PP / injection molding

Description:  For the first time, a polymer composite has replaced magnesium in a structural seat-cushion frame and under-seat storage lid for a front center 20% seat with integrated restraint system. The application is weight neutral and lower cost (≈$4 USD/unit), and satisfies all safety and crashworthiness requirements. Its flexible architecture allows for updates with future enhancements. Injection molded 40% LFT-PP is used to mold the frame, which also features an expanded polypropylene (EPP) antisubmarine foam block and a lockable ergo-latch. The assembly represents a significant reduction in carbon footprint vs. magnesium and has yielded 2 awarded and 2 pending patents.

Next Generation Armrest for Side Impact

OEM Make & Model: 2016 Ford Motor Co. Ford Super Duty pickup

Tier Supplier/Processor:  Yanfeng USA Automotive Trim Systems Company, Inc.

Material Supplier / Toolmaker: LyondellBasell / ToolPlas Systems Inc.

Material / Process:  SG702  PP & multiple / injection molding

Description:  Minimizing door intrusion during side impacts usually requires intensive body-structure countermeasures. Abdomen criteria for 5th and 50th percentile dummies are primarily driven by door-trim armrest stiffness during side impacts. This new door-trim armrest improves safety as a tuning component by acting as a load limiter and absorbing energy. Comprised of a skin, foam pad, PP-nonwoven trampoline fabric, ABS armrest substrate, and PP trampoline frame, the system is significantly softer than previous designs, substantially outperforming static and dynamic functional requirements without adding countermeasures, cost, or weight. Further, armrest durability improves 6 times, and costs and weight are reduced $31.80 and 3.8 kg per vehicle.

Modular Composite Front-Seat Cushion Pan

OEM Make & Model: 2017 Ford Motor Co. Lincoln Continental luxury sedan

Tier Supplier/Processor: Leggett & Platt, Great Lakes Trim & Grammer Industries / Engineered Plastics, Grand Traverse Plastics & Johnson Electric

Material Supplier / Toolmaker: BASF Corp., Advanced Composites, Inc. & DuPont Automotive / MacLean-Fog, Commercial Tool & Die & Johnson Electric

Material / Process:  ULTRAMID B3ZG7 OSI PA, ADX 5017 TPO, Delrin 100P NC010 POM / injection molding

Description:  This patent-pending, plastics-intensive, modular composite front seat-cushion pan (in impact-modified 35% GR PA), side-airbag deployment back panel (in talc-filled TPO), and power head-restraint drive nut (in POM) create a robust and dynamic crash-energy management system for front impact protection, side airbag deployment, and energy management for occupant impact protection. Further, the system enables modular assembly and scalable features for assembly ease.  Already 83 patents have been filed and 12 granted on this innovative seat system.

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

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® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.

29
Oct
16

Process, Assembly & Enabling Technologies Category Finalists Announced for 2016 #SPEInnovationAwards Competition

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The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Process, Assembly & Enabling Technologies Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: PROCESS, ASSEMBLY & ENABLING TECHNOLOGIES

Zipper Clip

OEM Make & Model: 2017 General Motors Co. Chevrolet Malibu midsize sedan

Tier Supplier/Processor: 3 Dimensional Services Group

Material Supplier / Toolmaker: Celanese Corp. / 3 Dimensional Services Group

Material / Process:  Celcon M90 POM / injection molding

Description: The zipper clip is a plastic solution that gives the holding benefits of a stud-and-nut combination while reducing production limitations. Ideal for use where a nut is desired but not feasible, this is the first stud insert with 4 ratcheting control features and a self-centering 2-way locator that holds over 120 lb/54.43 kg of weight while it requires low ergonomic effort (5.11 lb/2.32 kg) for assembly. The design reduces spring back as well as weight and cost and eliminates the need for assembly equipment as well as an isolator, since it protects the stud from corrosion.

Hot-Gas Welded Thermostat Housing Assembly

OEM Make & Model: 2017 Ford Motor Co. 3.5L V6 Cyclone TiVCT GTDI engines

Tier Supplier/Processor: Plastic Tec – Bocar Group

Material Supplier / Toolmaker: DuPont Automotive / Schweiger GmbH & Co. KG

Material / Process:  Zytel HTN HTN51G35HSLR BK420 PPA / injection molding & hot gas welding

Description:   Hot-gas welding joins both halves of this 35% GR-PPA thermostat housing assembly. The part has a small welding-flange footprint but high weld strength because there is no fiber/material degradation during the joining process. In fact, it is the only welding process that permits bridging of glass across the joint. The weld distance is held within 0.1 mm, enabling parts to package into very limited spaces with tight tolerances. Since the part is not touched during welding, there is no sticking. Versus previous aluminum solutions, the PPA assembly is 30% lighter and 40% less costly.

Two-Shot Map Lamp Lens

OEM Make & Model: 2017 Ford Motor Co. Lincoln Continental luxury sedan

Tier Supplier/Processor:  Flex Auto (Flextronics)

Material Supplier / Toolmaker: SABIC / Flex Auto (Flextronics)

Material / Process:  Lexan 143R HFD1830 PC / 2-shot injection molding

Description:  A redesigned capacitive touch lens produced via 2-shot molding eliminates molding defects while maintaining an ideal bonding surface and clear aperture for best light intensity. Eliminating a second tool, the Fresnel pattern is molded into the core of the first shot, which becomes the cavity of the second shot as the latter is layered over the former, keeping both outer surfaces smooth. Using 2 grades of PC with a 40o difference in heat-deflection temperature (HDT) eliminates the problem of the second shot melting the first during overmolding. Eliminating a tool reduced costs 25%.

Robotic Laser Cutting and Welding of TPO Fascia

OEM Make & Model: 2017 General Motors Co. Chevrolet Camaro ZL1 sports car

Tier Supplier/Processor: Magna Exteriors, Inc. / Magna Exterior – DexSys

Material Supplier / Toolmaker: LyondellBasell / Jenoptik AG

Material / Process:  Hifax TYC1168X TPO / injection molding

Description:  A hydraulic punch and sonic welding operation was replaced by robotic laser cutting and welding of a Class A exterior fascia. Unlike other welding processes, it is not necessary to thicken wallstock in weld areas to prevent readthrough with robotic laser welding of brackets on the backside of the part, and that reduces weight slightly. It also eliminates the need for contoured horns and punches. Clean cuts can be made in 1 sec on the painted side of the part. The dual-function process provides greater flexibility between programs and reduces floor space and tooling costs.

Assisted Positive-Locking Junction Box

OEM Make & Model: 2016 General Motors Co. Chevrolet Camaro sports cars

Tier Supplier/Processor: Yazaki North America Inc.

Material Supplier / Toolmaker: DuPont Automotive / Yazaki North America Inc.

Material / Process:  Multiple / Multiple

Description:  This tool-less, single-lever, self-locking underhood bussed electrical center (UBEC) guarantees proper connections for 4 connectors from 4 different wire harnesses using 1 hand and low assembly effort. There is no need to re-orient the UBEC to install mating connectors during OEM assembly. The result is a robust, high-circuit-capacity design that s ergonomically friendly to assembly-line workers. Additional benefits are a 7% weight savings, 8% additional spare electrical content, 10% reduction in overall footprint, better water-ingress protection, and 30% less assembly time.

 

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

# # # # #

® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.

28
Oct
16

Powertrain Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Powertrain Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: POWERTRAIN

Air Intake Manifold

OEM Make & Model: 2015 Volkswagen AG EA21 1.6L engines

Tier Supplier/Processor: Hua Tao Ltd.

Material Supplier / Toolmaker: SABIC / Not stated

Material / Process: SABIC G3135X PP / injection molding

Description:  This is the first air-intake manifold launched in China using 35% GR-PP to replace PA 6/6. The application provides 25-30% cost reduction and 15-20% molded-part weight reduction while retaining properties at high temperatures and improving weld strength, andNVH levels by 5 dB. Unique technology involving finer glass fibers and special sizing helps meet performance requirements. Parts are vibration welded.

Active Fuel-Management System

OEM Make & Model: 2012 General Motors Co. 5.3L V8 LH6 engines

Tier Supplier/Processor: Eaton Corp. Plc. / ITW Global Automotive

Material Supplier / Toolmaker: SABIC / Not stated

Material / Process:  Ultem 2310 polyetherimide (PEI) / injection molding

Description:  To boost fuel efficiency and reduce emissions on classic small-block pushrod V8 engines, an inexpensive and simple technology called active fuel management (displacement on demand) was developed. The efficient and precise electro-mechanical hydraulic system deactivates cylinder valves when power is not needed, then reactivates them when power is called for again. An important component of the system’s solenoid control valves is injection molded from 30% GR-PEI. The material is used for its high stiffness, creep resistance, thermal and chemical resistance, high knitline strength, and ability to be ultrasonically welded. The system improves fuel efficiency 5.5-7.5% and reduces cost 30% vs. metal.

2.0L GTDI Turbo Compressor Outlet Duct

OEM Make & Model:  2017 FCA Alpha Romeo Giulia luxury sedan

Tier Supplier/Processor: ABC Group, Inc.

Material Supplier / Toolmaker:  BASF Corp. / ABC Group, Inc.

Material / Process:  Ultramid Endure D5G3 BM PA 6/6 / 3D flashless blow molding

Description:  To meet more stringent fuel efficiency and tailpipe emissions requirements, engines increasingly are being downsized and turbocharged, but that raises temperatures and pressures that underhood components see during operation. For example, charge air ducts, which take air from the turbocharger to the throttle body, can see continuous-use temps as high as 220C and pressures as high as 207 KPa. Further, compact packaging space requires efficient designs. Switching to a heat-stabilized PA 6/6 capable of being 3D flashless blow molded reduced mass 30-40% and cost 20-25% vs. metallic designs.

 

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

# # # # #

® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.

27
Oct
16

Materials Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Materials Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: MATERIALS

NVH Baffles

OEM Make & Model: 2016 Ford Motor Co. Ford F-150 pickup

Tier Supplier/Processor: Henkel AG & Co. KGaA / Henkel AG & Co. KGaA & Wittmann Battenfeld, Inc.

Material Supplier / Toolmaker: Henkel AG & Co. KGaA / Creative Die Mold Corp.

Material / Process:  EcoLon GF1960 PA 6/6 (100% post-consumer recyclate (PCR)) & ethylene vinyl acetate (EVA) / injection molding

Description:  Because aluminum body panels expand at twice the rate that steel ones do, a new baffle sealing package was needed that would maintain adhesion to the substrate during thermal expansion of the aluminum. It also needed to reduce or eliminate noise/vibration/harshness (NVH) throughout the vehicle to improve driver comfort through a quieter interior. A EVA expandable sealer with a blowing agent that activates during e-coat and produces an innovative elastic cross-linking network was developed to improve hot-tear strength and elongation vs. previous materials. The EVA foam is injection overmolded onto a PA substrate.

Rhapsody Blue MIC Vehicle Environment

OEM Make & Model: 2016 Ford Motor Co. Lincoln Continental luxury sedan r

Tier Supplier/Processor: Americhem Inc. / Multiple

Material Supplier / Toolmaker: Americhem Inc. & Multiple / Multiple

Material / Process: Multiple PP, TPO, ABS, PA, POM / Multiple

Description:  Project goals were to achieve a unique MIC color space that looks luxurious but appeals to today’s generation. It involved using the first transparent pigment-based interior color deliverable across 76 base resins for the vehicle interior. Once the color was mastered, early attempts showed it was prone to metamerism with a red/green directional hue shift. Numerous attempts to achieve color consistency bidirectionally with standard pigment adjustments did not solve the problem. Finally, the color was remastered using a non-titanium dioxide (TIO2) system that did not exhibit hue shift, eliminating the need to paint and creating a calming, cool color environment.

Vacuum Brake Tubes

OEM Make & Model: 2016 General Motors Co. Chevrolet Silverado & GMC Sierra pickups

Tier Supplier/Processor: Cooper Standard

Material Supplier / Toolmaker:  DSM Engineering Plastics / Not stated

Material / Process:  Arnitel CM622 thermoplastic polyester elastomer (TPC-ET) /Not stated

Description: A high-performance thermoplastic was needed for vacuum brake tubing to replace reinforced rubber. It needed broad temperature performance (-40-150C), chemical resistance, burst strength to 60 bar minimum and flexural strength to 50 N minimum. It also had to resist vacuum collapse after 2 hr @ 150C and provide impact retention after 336 hr @ 150C. The design was changed to use a smaller diameter, thinner wall to simplify engine / undercarriage routing and eliminate heat shields plus allow quick connects. A TPC-ET elastomer with high thermal oxidative stability was developed. It is 30% lighter, less costly, and eliminates brackets.

Lightweight TPO Bumper Cover

OEM Make & Model: 2017 Hyundai Motor Group Hyundai Genesis G90 luxury sedan

Tier Supplier/Processor: ECO Plastic

Material Supplier / Toolmaker:  Hanwha Total Petrochemicals Co., Ltd. / Hyundai Motor Group

Material / Process:  NB71 TPO / injection molding

Description:  A new, lighter weight TPO bumper cover was developed using high-crystallinity PP, ethylene-octane rubber, and a combination of nano-size talc and micron-size whisker fillers similar to magnesium oxysulfate.  The material provides high mechanical performance, improved dimensional stability, and low coefficient of linear thermal expansion (CLTE) thanks to the high aspect ratio filler. Weight is reduced 7-10% and the material is cost neutral vs. the material it replaced. Additionally, 6 patents have been obtained on the development.

 

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

# # # # #

® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.

26
Oct
16

Environmental Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Environmental Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: ENVIRONMENTAL

Electronic Power-Steering Pulley

OEM Make & Model: 2017 General Motors Co. GMC Acadia sport-utility vehicle (SUV)

Tier Supplier/Processor: Nexteer Automotive / PRISM Plastics

Material Supplier / Toolmaker: DSM Engineering Plastics / Not stated

Material / Process:  Stanyl TW241F12 PA 4/6 / injection molding

Description:  Project goals were to find ways to reduce cost without reducing performance of the electric power-steering gear-assist mechanism by replacing a powdered metal pulley with an injection molded plastic one. A high-flow grade of 60% GR-PA 4/6 that produces a resin-rich surface for improved belt wear was selected. It offers significant cost savings and reduces mass over 50% vs. the metal pulley. Its assembly method eliminates 3 bolts, which are replaced by a retaining ring. The molded torque tooth provides secure orientation and excellent load-carrying capabilities.

Closed-Loop Recycling of Bottles

OEM Make & Model: 2016 General Motors Co. (GM) Chevrolet Equinox & GMC Terrain cross-over utility vehicles (CUVs)

Tier Supplier/Processor: Exo-s / Rogers Foam Co.

Material Supplier / Toolmaker: Wm. T. Burnett & Co. / Not stated

Material / Process:  Nonwoven from recycled polyethylene terephthalate (PET) / Multiple

Description:  This innovative, multi-stakeholder, cost-neutral recycling project protects the environment, grows local economies, creates jobs, and helps people in a sustainable manner. Water bottles collected at GM operations and from the Flint, Michigan, U.S.A. area are directed into a supply chain that recycles the material into nonwoven fleece for specific applications including engine manifold cover insulation, insulation for coats that convert to sleeping bags for the homeless and are made by formerly homeless women as part of a jobs program, and air filters that purify the air at numerous GM and other manufacturing operations. Already 3.5-million water bottles have been repurposed.

Biomass-based Polyester Blend

OEM Make & Model: 2015 Hyundai Motor Group IONIQ EV

Tier Supplier/Processor: Seoyon E-Hwa Interior Systems Manufacturing

Material Supplier / Toolmaker: SK Chemicals / Not stated

Material / Process:  Skytra bio polyester (PETG/ABS) / Not stated

Description:  The goals of this project were to develop a high-biomass-content thermoplastic polyester blend for window panels and steering-wheel bezels using biomass-based PETG — reportedly the first application in the world. The optimized PETG/ABS composition was used to replace a PC/ABS blend. Benefits include a 57% reduction in carbon emissions (145 tons/year), an 88% reduction in VOCs, and a significant increase in molded part chemical resistance. By weight, the biomass content is 25% and by C14, the biomass content is 14%.

 

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

# # # # #

® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.

25
Oct
16

Chassis & Hardware Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Chassis & Hardware Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: CHASSIS & HARDWARE

Strut Mount

OEM Make & Model: 2016 General Motors Co. Cadillac CT6 luxury sedan

Tier Supplier/Processor: ContiTech North America, Inc.

Material Supplier / Toolmaker: BASF Corp. / Not stated

Material / Process:  Ultramid A3WG10CR 50% glass-reinforced (GR) PA 6/6 / injection molding

Description:  This is the first use of a glass-reinforced PA material for strut-mount housings on all 4 corners of a vehicle and the first application of polyamide housings on the front and rear suspension systems. The injection molded parts integrate common components for both front and rear mounts, and employ a special thread assembly method with a locking feature.  They reduce mass 30% vs. typical steel and aluminum parts and reduce noise transmission through the suspension system. Thanks to modular assembly, the design also offers greater tuning flexibility.

Rear Differential Cross-Member

OEM Make & Model: 2016 Daimler AG Mercedes S-Class luxury sedan

Tier Supplier/Processor: ContiTech North America, Inc.

Material Supplier / Toolmaker: BASF Corp. / Not stated

Material / Process:  Ultramid A3WG10CR 50% GR-PA 6/6 / injection molding

Description:  This is said to be the first application where a PA/glass composite has been used as a cross-member to support the rear differential and complete the rear cradle of a vehicle. By replacing traditional parts in steel or aluminum, the injection molded glass-reinforced PA 6/6 design offered parts integration opportunities, is cost neutral, reduces noise transmission from the driveshaft, and reduces mass 25%, helping improve fuel economy and reduce tailpipe emissions. The grade used has been optimized for dynamic loads and is controlled with tighter production specifications.

Latching Refueling Valve

OEM Make & Model: 2017 Ford Motor Co. Ford Fusion & Lincoln MKZ hybrid EVs

Tier Supplier/Processor: Continental Automotive / Advanced Molding Tech – USA

Material Supplier / Toolmaker: DuPont Automotive / Xinpoint

Material / Process:  Zytel HTNWRF51G30 30% GR polyphthalamide (PPA) / injection molding

Description:   This challenging new design demanded a unique material with consistent properties after prolonged exposure to fuels, superior wear characteristics, stable coefficient of friction over a wide temperature range, superior fuel swell and exposure resistance, and superior molding capabilities to properly fill tight-tolerance micro-features. An injection molded 30% GR-PPA with polytetrafluoroethylene (PTFE) micro-powder (to enhance wear characteristics) met all requirements. The application saved over $10 USD/vehicle and reduced energy consumption vs. the previous valve. The novel technology has led to 1 issued and 7 pending patents.

Outer Handle

OEM Make & Model: 2017 Ford Motor Co. Lincoln Continental luxury sedan

Tier Supplier/Processor: ADAC Automotive

Material Supplier / Toolmaker: SABIC / not stated

Material / Process: Cycoloy C1200HF PC/ABS / injection molded

Description:  This application is industry’s first belt-integrated, outside door handle with switch activation to open both front and rear doors. The slender, minimalist, all-plastic, high-luster chrome-finish handle provides effortless operation, luxury feel, and quiet operation. The injection molded PC/ABS part with integrated zinc casting also features an e-handle with power-release switch to deliver a sleek, uninterrupted form that reduces mass 20% and cost 35% vs. conventional bond-on-bracket designs.

 

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

# # # # #

® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.

24
Oct
16

Body Interior Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Body Interior Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: BODY INTERIOR

Ultrathin Seat Back

OEM Make & Model: 2017 General Motors Co. Chevrolet Bolt EV

Tier Supplier/Processor: General Motors Co. / USF

Material Supplier / Toolmaker: Advanced Composites, Inc. / ToolPlas Systems Inc.

Material / Process:  GMW15548P-PP/polyethylene (PE)-M15-Type 6A, GMW15548P-PP/PE-M20 Type 4, GMW16582P-PA6-GF15 / injection molding

Description:  To solve the challenges of conventional seat construction, which limits console storage and rear-seat leg room, this product eliminates molded urethane foam from the seat back and replaces it with an all-plastic shell featuring a larger concave region that enables optimum occupant comfort. An innovative suspension system also is used that consists of a forward plastic seat back panel attached to the frame via spring joints. The technology can increase front console width by ≈ 0.8 in./20 mm and reduce seatback thickness by ≈ 2.1 in./52 mm while reducing overall vehicle cost $35-$40 USD and mass 3-4 kg.

Thin-Wall IP Substrate

OEM Make & Model: 2017 Ford Motor Co. Lincoln Continental luxury sedan

Tier Supplier/Processor: Faurecia & Detroit Manufacturing Systems Ltd., LLC / Faurecia

Material Supplier / Toolmaker: SABIC / Lamko Tool & Mold Inc.

Material / Process:  Stamax 30YK270E 30% LFT-PP / injection molding

Description:  Reportedly, this is the thinnest full-size, deep-draw injection molded instrument panel (IP) in North America at 1.9 mm/0.07 in. It was achieved by injection molding a 30% glass-reinforced LFT-PP. Versus the 2.4 mm/0.09 in. microcellular-foam molded benchmark, this design was 14% lighter, saved over $1 USD in materials as well as the microcellular-foaming investment, and helped optimize packaging. Moldfilling analysis with fiber orientation was used for accurate warpage predictions and to develop tooling countermeasures to facilitate molding.

Composite Suspensions for Upper and Lower Backs

OEM Make & Model: 2017 Ford Motor Co. Lincoln Continental luxury sedan

Tier Supplier/Processor: Leggett & Platt Inc. & Magna International / Summit Plastic Molding & Century Plastics

Material Supplier / Toolmaker: BASF Corp., Advanced Composites, Inc., DuPont Automotive / Summit Plastic Molding & Mega Mold

Material / Process:  Ultramid B3ZG7 OSI PA; Ultramid B3EG3 PA; ADX 5017 TPO; Delrin 100 polyoxymethylene (POM) / Multiple

Description:  Thanks to integrated composite designs, this “perfect position seat” suspension system delivers tuned suspension to optimize occupant comfort by cradling the upper back and providing side-torso support, which flexes to accommodate various occupant sizes. Special attachment features facilitate assembly and service time. The design also creates a robust dynamic crash-energy management system for rear-impact protection. Molded-in-color is used for A surfaces and craftsmanship. The system, for which 83 patents have been filed, reduces total seat weight by 8% and cost by 15% despite adding more features.

Quad-Barrel Convertible Cupholder

OEM Make & Model: 2017 Ford Motor Co. Ford Super Duty pickup

Tier Supplier/Processor: Summit Polymers, Inc.

Material Supplier / Toolmaker: SABIC / Not stated

Material / Process: Cycolac XCY620 PC/acrylonitrile butadiene styrene (ABS) / injection molding

Description:  This console design converts from 2 cupholders plus a bin to 4 cupholders with the help of a patented slider tray assembly for greater user flexibility without the need to remove and stow components when not in use. The design of the injection molded PC/ABS cupholders accommodates beverage containers ranging from small coffee cups and water bottles to large all-day beverage containers while reducing weight 70% vs. the outgoing model and lowering costs $3 USD depending on content replaced.

 

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

# # # # #

® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.

23
Oct
16

Body Exterior Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Body Exterior Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: BODY EXTERIOR

Structural Front End Module with Active Grille Shutter

OEM Make & Model:  2016 Ford Motor Co. Ford SuperDuty pickup

Tier Supplier/Processor: Shape Corp.

Material Supplier / Toolmaker: Celanese Corp. / Not stated

Material / Process:  Celstran 40-20 Black long-fiber thermoplastic (LFT) polypropylene (PP) / injection molding

Description:  This all-composite design without metallic reinforcement is the first active grille shutter (AGS)-capable, injection-molded LFT-PP front-end module (FEM) bolster used on a heavy-duty pickup platform. Replacing steel and plastic/metal hybrids at a 3 lb/1.4 kg and $3 USD savings/vehicle, the design offers parts consolidation with locating features that aid fit & finish, improves airflow, while meeting structural requirements for part deflections of <1mm on this 8,500 lb/3,856 kg class vehicle.

Lightweight Glass

OEM Make & Model: 2017 Ford Motor Co. Ford GT40 supercar

Tier Supplier/Processor: Pittsburgh Glass Works LLC

Material Supplier / Toolmaker: Sekisui Chemical Co., Ltd. / Pittsburgh Glass Works LLC

Material / Process: polyvinyl butyral (PVB) /multiple

Description:  Three of five glass positions on this vehicle feature chemically tempered glazing that is part of a thin, hybrid laminate solution with an interlayer of solar-control PVB film that reduces glazing weight approximately 37% while lowering heat transmittance to keep interiors cooler. Versus conventional 0.20 in./4.96 mm thick laminates featuring 2 layers of soda-lime glass (SLG) with a PVB interlayer, the new construction features standard-thickness layers of SLG and PVB plus a very-thin (0.03 in./0.7 mm) layer of chemically tempered glass for a total thickness of 0.14 in./3.56 mm. The resulting laminate is thinner, lighter, tougher, and offers optical advantages.

MIC High Gloss Body Color TPO Fascia

OEM Make & Model: 2017 Ford Motor Co. Ford Transit Connect van

Tier Supplier/Processor: Magna Exteriors, Inc. / Magna Exteriors, Inc. – Nascote

Material Supplier / Toolmaker: Advanced Composites, Inc. / Tycos Tool & Die

Material / Process:  ADX700 ADX70004WFA thermoplastic polyolefin (TPO) / injection molding

Description:  Painted fascias are prone to chip and peel, which leads to warranty costs and customer unhappiness. Additionally, painting adds significant cost with negative environmental impact. Instead, a high-gloss, weather- and mar-resistant, molded-in-color (MIC) TPO material matched to vehicle body panel color. Rigorous testing was conducted to assure the material was resistant to stone pecking and road chemicals and would not change shape when exposed to high heat. Additionally, a lens-grade mold with SP1 diamond polish and gating designed to minimize knitlines was used. The resulting part is 10% lighter, offers $800,000 USD annualized savings, and harmonizes with exterior painted components.

3D Radiator Grille

OEM Make & Model: 2017 General Motors Co. Chevrolet Bolt electric vehicle (EV)

Tier Supplier/Processor: Sam Shin Chemical Co.

Material Supplier / Toolmaker: LG Chem Ltd. / A-Tech Solution Co., Ltd.

Material / Process:  Lupoy 1000MU polycarbonate (PC)

Description: A new appearance is achieved for this front grille by using “varied contouring” (variable wall thicknesses) on the B side of this injection molded, tinted PC part, which subsequently is UV coated on the A side and receives a 3-coat paint system on the B side. The end result is a unique 3D look on a 2D surface.

 

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

# # # # #

® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.

22
Oct
16

Aftermarket Category Finalists Announced for 2016 #SPEInnovationAwards Competition

IAG16Masthead2

The Automotive Division of the Society of Plastics Engineers (SPE®) today announced the Aftermarket Category finalists for its 46th-annual Automotive Innovation Awards Competition, the oldest and largest recognition event in the automotive and plastics industries. Nominations were first subjected to a pre-qualification review and then were presented before a panel of industry experts on September 29-30, 2016. That panel sent forward the most innovative nominations (category finalists) to the Blue Ribbon judging round, which was held October 10, 2016. Category and Grand Award winners selected during the Blue Ribbon judging round will be announced on the evening of November 9, 2016 during the 46th SPE Automotive Innovation Awards Gala.

 

CATEGORY: AFTERMARKET

Dual-Option Insert Carbon Fiber Composite Fuel-Filler Door

OEM Make & Model: 2017 General Motors Co. Chevrolet Camaro sports car

Tier Supplier/Processor: Polytec FOHA Inc. / NOVO Plastics Inc.

Material Supplier / Toolmaker: Mitsubishi Rayon Co., Ltd., SABIC, & Basler / Integrity Tool & Mold Inc.

Material / Process:  Pyrofil carbon fiber, Noryl GTX modified-polyphenylene ether (MPPE)/ polyamide (PA 6); Urethane TR; clearcoat / injection or compression molding

Description:  This fuel-filler door design features inserts of either injection molded and painted MPPE/PA6 (in black, metallic silver, or red to match body paint) or compression molded and clear coated carbon fiber-reinforced composite with visible weave. The unique design of the system accommodates either the 2.0 mm-thick injection molded or the 1.0 mm-thick compression molded insert. The specially designed tool enables the Camaro name (with a 0.25 radius) on the fuel-filler door to be painted. Proprietary material is used for the visible-weave carbon composite version and a special clear coat on that insert offers 75% cost savings.

 

Carbon Fiber Composite Spoiler

OEM Make & Model: 2016 General Motors Co. Chevrolet Corvette sports car

Tier Supplier/Processor:  deBotech, Inc.

Material Supplier / Toolmaker: Solvay / deBotech, Inc.

Material / Process:  Solvay MTM5790 epoxy

Description:  This 1-piece aftermarket epoxy/carbon fiber spoiler provides a premium carbon composite appearance and enables the same aerodynamic performance as production 3-piece spoilers with different aero variants while also reducing mass by 40%. The spoiler’s unique design and proprietary tooling combines solid wickerbills and an open cavity blade plus integral threaded inserts to facilitate manufacturing and assembly. The 1-piece construction offers a cleaner appearance due to reduction of fasteners. The spoiler is offered in both clear coat with exposed weave and painted in carbon flash metallic paint.

 

Interested in attending this year’s event?  There is still time to buy individual tickets or tables of 10 seats. Register here.

For more information, see http://speautomotive.com/inno and http://speautomotive.com/awa .

# # # # #

® SPE is a registered trademark of the Society of Plastics Engineers. All other trademarks are the property of their respective owners.




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