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Summary: First thermoplastic GOR able to withstand the 400 F degree heat of e-coating curing process. Specially formulated DuPont™ Rynite® enables the GOR to endure the entire production process, significantly simplifying vehicle assembly while improving fit of front end components.
Weight Savings: 10 to 15% compared to SMC.
Cost Savings: 15% less than SMC version.
Most Innovative Feature: First thermoplastic GOR able to withstand the 400 F degree heat of e-coating curing process, also reduces weight by 10 to 15% and cost by 15% compared to sheet molding compound (SMC).
Other Innovative Features: Specially formulated DuPont™ Rynite® enables the GOR to endure the entire production process, significantly simplifying vehicle assembly while improving fit of front end components.
Forming Process: Injection molding using two molds in one press.
First time process used?: Yes.
Previous Process Used: Comparable component of SMC thermoset requires secondary operations to produce over 70 drilled, punched and milled holes that generate considerable non-recyclable scrap.
Tooling Innovations: Two large molds are married together to produce two one-piece GORs in a single shot. An 'H' manifold system moves material into four directions and is then directed into the mold through for each part through 14 gates.
New Material Developments: Specially formulated Rynite® withstands temperature spikes up to 400 F degrees, while unique crystalinity and moisture resistance delivers outstanding dimensional stability.
Weight Savings: GOR weighs 10 to 15% less than SMC.
Direct Cost Savings: Cost is 15% less than SMC version.
Indirect Cost Savings: Thermoplastic GOR enables automation of vehicle front-end component assembly, significantly reducing complexity and helping to improve alignment of components, reducing potential warranty costs.
Direct Consumer Benefit: Improved fit/alignment of headlights, fenders and fascia is made possible through design and material innovations to enhance vehicle appearance. Weight reduction helps improve fuel economy. Lower part costs helps relieve upward vehicle sale price pressure.
Translates to other Vehicles?: This thermoplastic GOR has the potential to benefit a number of vehicle lines by contributing further cost reduction through increased integration of parts compared to SMC. More thermoplastic GOR development programs are underway.
Safety Benefits: Tough, durable GOR protects the proper alignment of vehicle headlights.
Environmental Benefits: Thermoplastic material can be melt recycled, and thermoplastic manufacturing process is more environmentally friendly than SMC process.
