SABIC Innovative Plastics displayed a door module with an integrated window guide rail made from its STAMAX long glass fiber polypropylene resin. The door module helped Hyundai-Kia Motors win a Society of Plastics Engineers Innovation Award in 2010. The redesign using this 30 percent glass-reinforced resin replaced steel in all four door panels, cut total vehicle weight by approximately 4 pounds (2kg), allowed the integration of 21 components into a single injection-molded part, and cut overall system costs by combining five assembly processes in one. (Source: SABIC)
Interesting slide show, Ann. It's pretty amazing what they can accomplish today via use of bioplastics and innovations in injection molding processes. It seems like a lot of the lightweighting work takes place in the dash system. It strikes me that there should be a lot of other opportunities, particularly in the frame, to take weight out of the vehicle makeup.
Thanks for sharing this. Lots of great possibilities here.
I think the dash is the easiest application but the last slide stel in the door panels was replaced. I wonder how lightweight plastics have been/will be used in motorcycle helmets? And, how long do they last? The moving parts are constantly used and safety is the main concern in such a small space.
Thanks, Beth. There are many opportunities to take weight out of the frame and structure via composites, but there are assembly and process issues involved with transferring those technologies to highly automated, high volume automobile manufacturing. Meanwhile, lightweight metals production for cars is also being studied and occasionally applied, though usually, like composites, to high end race cars and more customized apps.
Ann: I ride a motorcycle. My curiousity is around appllying the newer lightweight plastics to helmets. Helmets have gotten much lighter over the years but there is a perception that heavy equals safe. Lightweight componets have been introduced over the years but tend to break off and need replacement with intense use.
I'd be concerned about using polycarbonate or PC/ABS for the hood of a tractor. These materials are known for poor environmental stress cracking resistance, especially when exposed to fuel or oil. Friends have told me about having this problem with other injection molded tractor hoods.
By the way, it seems like the images for slide 2 and slide 10 have been switched. Slide 2 shows a door module, but the text is about a tractor hood. Slide 10 shows a tractor, but the text is about a door module.
This is great. Plastics (a variety of them) have been used in firearms frames for a while. That is a demanding application, and they last. The next step is to bring back aerodynamics. The trend toward SUVs and cross-overs (or station wagons, as they should be called) has hurt fuel economy at least as much as increased weight. I understand that most of the weight increase is the result of safety measures. Using plastics will help mitigate some of that.
The lightest parts are inflated parts with the internal pressure adding to get rigidity. Too bad space is such a premium on cars. Maybe the wheels and some structual body parts could benefit from this technology. (might add a softer collision factor in an accident)
I worked in the motorcycle business for many years. Helmets have always been the trickiest thing to make. Plastic helmets have been manufactured, but the best, lightest helmets have always been fiberglass. The reason is that the plastic shells were actually too durable! Thin fiberglass can be talored to crush and abrade at specific rates. The shell actually is designed to crumple like the front and rear zones of modern cars. The newest plastics will probably be able to take over soon, but so far the best helmets are fiberglass construction.
A slew of announcements about new materials and design concepts for transportation have come out of several trade shows focusing on plastics, aircraft interiors, heavy trucks, and automotive engineering. A few more announcements have come independent of any trade shows, maybe just because it's spring.
At the JEC Europe 2015 composites show in Paris last month, makers of composite materials, software, and process equipment showed off their latest innovations. This year's show saw some announcements related to automotive applications, but many of the improvements came in the world of aerospace.
The DuPont-sponsored Plastics Industry Trends survey shows engineers want improved performance in a broad range of plastics and better recycling technology. These concerns top even processing enhancements that improve productivity.
Plastics leader SABIC recently announced a global initiative to help its customers take advantage of additive manufacturing (AM) and also advance 3D printing (3DP) technologies in several application areas. The company's plans go way beyond materials, and also include design, processing, and part performance.
A theme that was reflected in several ways at NPE 2015 was the use of 3D printing to assist in, or improve on, injection molding, as well as improvements in 3D printing materials and processes that are making better functional prototypes and end-use parts.
Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies. You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived. So if you can't attend live, attend at your convenience.