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 Mold-In-Color Rubstrips for Fascia
Assemblies |
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| Application Description: The molding to fascia interface design comprehends both manufacturing variation and life cycle thermal growth variation. An integral attachment geometry is used for assembly. | Single Most Unique Feature: The design concept to comprehend part size variation and the analytical techniques used for validation provided an aesthetically appealing assembly with improved product durability. |
| Process Descriptions: Painted, injection molded fascia shell with mold-in-color rubstrip. | First Usage of Process?: Yes, this is the first instance where a one piece, wheel well to wheel well assembled rubstrip is in production. |
| Formerly Used Process: The previous design fascia required a secondary, separate masking operation prior to paint to achieve the desired rubstrip design effect. | Tooling Innovations: A sequentially valve gated hot runner system is incorporated into both fascia and rubstrip molds using some direct drops into the part surface. |
| Material Innovations: As a result of this design concept change, the fascia can be molded using a more cost-effective, non-UV stable reactor grade resin. | Mass Savings: There are no weight savings. |
| Cost Savings: Direct Cost Savings: $1.7 million/annum | Cost Avoidance: Indirect Cost Savings: $280,000/annum |
| Direct Consumer Benefit: Repair costs are reduced as the rubstrip can now be replaced instead of replacing the entire assembly. In addition, the aesthetic appeal of the fascia assembly is improved through crisper accent and styling lines. The assembly has a more expensive look and feel. | Is Technology Transferable?: This design concept can be incorporated into virtually any application where styling or function dictate multiple surface finishes or materials within one component or assembly. |
| Significant Safety Benefit: There are no direct safety improvements. | Significant Environmental Benefit: There is a reduction in the amount of scrap fascias going to landfill made possible by the modular design. The component can be replaced without replacing the entire assembly. |
| Additional Information: This program was completed to launch within 10 months. The program included product design, prototype, tool build, validation and implementation. The industry standard timing for this type of program is 24 to 30 months. The main drive behind this redesign activity was to ensure a steady supply of good quality, robust product to our customer. Various yield and part quality issues with the previous design prevented Polycon from achieving this goal. |
Snap Fit of Rub Strip onto Bumper |
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Riveted Attachment of Reinforcement Strip |
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