(click on the images to see larger illustrations)
| Materials - Entry 19 |
WINNER |
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| Two-Shot Load Bearing Touch-Off Molding 2005 Ford Mustang |
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| System Supplier: | Cooper Standard Automotive | |
| Molder: | Innatech | |
| Tooling Supplier: | Dynamic Mold | |
| Material Supplier: | A. Schulman/Zeon Chemicals | |
| Resin: | Schulamid/Zeotherm PA 66/6 GF33H-31/100-80B GF PA 6/6 TPV | |
| This is the first time an all plastic component has been used as a load bearing touch-off molding on a convertible. This is a multi-shot application of glass filled polyamide and new TPV resin that is chemically bondable to the polyamide. The design also incorporates an innovative clip attachment to vehicle. | ||
| Materials - Entry 9 |
Finalist |
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| Static Dissipative Non-Slip Truck Bedliner 2005 Ford Pick-up Trucks |
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| System Supplier: | Durakon Industries | |
| Molder: | - | |
| Tooling Supplier: | - | |
| Material Supplier: | Solvay Engineered Polymers, Inc. | |
| Resin: | PE | |
| This multi-layer laminate truck bedliner incorporates static dissipative and non-slip properties for reduced likelihood of hydrocarbon explosion and improved load management. | ||
| Materials - Entry 16 |
Finalist |
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| 3.7L V-6 Engine Valve Cover 2005 DaimlerChrysler 3.7L V-6 engine |
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| System Supplier: | Dana Sealing Products Division | |
| Molder: | Dana Sealing Products Division | |
| Tooling Supplier: | Shaw | |
| Material Supplier: | Premix | |
| Resin: | Premi-glass 1266 SMC | |
| The 3.7L valve cover utilizes new polyester/vinylester thermoset hybrid resin. This material offers similar performance as a vinylester resin at a reduced cost. Application saved over 4 lbs per vehicle (versus steel) and was a 13% cost savings. Program was launched in record time (8-1/2 months). | ||
| Materials - Entry 14 | ||
| Ceramic Matrix Composite Clutch Plate 2005 Dr. Ing.h.c.F.Porsche AG Carrera GT |
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| System Supplier: | Sachs Race Engineering | |
| Molder: | SGL Carbon | |
| Tooling Supplier: | - | |
| Material Supplier: | SGL Carbon | |
| Resin: | Phenol | |
| A new ceramic matrix, carbon fiber reinforced material has been developed for use in clutch plates. The extreme heat and wear resistance of the new high strength material allows the construction of clutches with minimum diameter for road going cars. It combines race clutch technology with the durability of conventional car clutches. The use of woven carbon allows up to 20,000 RPM service due to the extremely high specific thermal stress resistance. | ||
| Materials - Entry 22 | ||
| Low Gloss PA/ABS Resin for Mirror Housings 2004 General Motors All Vehicles with On-Star |
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| System Supplier: | Magna Donnelly | |
| Molder: | Adkey, Inc. | |
| Tooling Supplier: | - | |
| Material Supplier: | BASF | |
| Resin: | Terblend N NM-19 ABS/PA6 | |
| This new PA/ABS resin achieves a low gloss and high quality matte finish without the use of paint. Terblend N PA/ABS is less dense than comparable materials, allowing for weight savings. The resin is also a high-flow material, so it is easy to mold in complex tools, and requires minimal adjustments for tooling and process conversions. | ||
| Materials - Entry 56 | ||
| High Strength, Low Density SMC 1996 General Motors Corvette, Cadillac XLR, Buick LeSabre, Pontiac Bonneville |
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| System Supplier: | Meridian, Budd Company | |
| Molder: | - | |
| Tooling Supplier: | - | |
| Material Supplier: | - | |
| Resin: | SMC | |
| Using a novel combination of thermoplastic and thermoset resins, a family of composite materials that gives a 30% mass reduction over conventional SMC has been developed. Some examples of the current applications are the inner panels of the Corvette and Cadillac XLR as well as the front-end support panels of Buick LeSabre and Pontiac Bonneville. | ||
