1999 SPE Award Winners:
Chassis/Hardware/Assembly Category

Grille Opening Reinforcement (GOR)

The grille opening reinforcement utilizes hybrid technology consisting of multiple sheet metal components over-molded with glass reinforced nylon.   The polymer serves to stabilize the sheet metal structures and helps to transfer force throughout the structure via reinforcing ribs and mechanical connections.  This concept replaced an original design consisting of ten metal components, that was unable to meet dimensional tolerance requirements.  In addition, the compressive, torsional and flexural strengths of the hybrid system exceeds that of conventional systems by 1.8 times.

The illustration above is an underneath view, showing the ribbing which provides structural rigidity.  The two pictures below show close ups of these molded features.

The precise repeatability of the injection molding process enabled a dramatic decrease in secondary fit and finish adjustments in assembly.  The integral functionality of this part includes positions for mounting of the hood latch, headlamps, and fenders.  This operation resulted in a cost savings of 30% and a weight savings of 40%, as well as reduced time and space requirements for manufacturing.