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| WINNER |
Chassis / Hardware - Entry 65 |
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All-Plastic Window Regulator |
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| OEM: | DaimlerChrysler | |
| Model: | PT Cruiser | |
| Model Year: | 2006 | |
| System Supplier: | DURA Automotive | |
| Molder / Processor: | Titan Plastics | |
| Toolmaker: | Titan Plastics | |
| Material Supplier: | Michael Day Enterprises | |
| Generic Resin Type: | PA 6/6 | |
| Resin Trade Name: | Gearcomp | |
| Grade: | 6001 | |
| Summary: This product is a lightweight highly efficient window regulator with all major components produced from plastic instead of steel. The simple design reduces part count over other conventional regulator designs. And the Racklift™ provides inboard/outboard flexibility that improves efficiency and reduces efforts and seal wear due to imperfect matching between the regulator and door glass path. | ||
| Finalist |
Chassis / Hardware - Entry 24 |
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Vacuum Brake Booster Valve Body |
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| OEM: | Mitsubishi | |
| Model: | Eclipse / Spyder | |
| Model Year: | 2006 | |
| System Supplier: | Robert Bosch Corporation | |
| Molder / Processor: | Friedrichs & Rath GmbH | |
| Toolmaker: | Friedrichs & Rath GmbH | |
| Material Supplier: | DSM Engineering Plastic | |
| Generic Resin Type: | PET | |
| Resin Trade Name: | Anite | |
| Grade: | AV2-370/B | |
| Summary: The reaction disc cup is a molded feature on this part, which allows for the mating steel part to be made via a less-complex manufacturing process. This provides cost savings in addition to a 34% weight reduction. The part has direct interaction with 18 other components, including 7 different vacuum sealing locations (3 of which are dynamic), and incorporates long air-flow features for fast booster response. | ||
| Finalist |
Chassis / Hardware - Entry 40 |
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Glass-Run Retainer Assembly |
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| OEM: | Ford | |
| Model: | Mustang | |
| Model Year: | 2005 | |
| System Supplier: | Cooper Standard Automotive | |
| Molder / Processor: | ELS Plastics Corporation | |
| Toolmaker: | Concours Mold Inc. | |
| Material Supplier: | BASF Corporation | |
| Generic Resin Type: | ASA | |
| Resin Trade Name: | Luran S | |
| Grade: | 778 T | |
| Summary: This traditionally multi-piece assembly is consolidated into one PIA that provides both glass and body sealing against water and noise intrusion. The component reduces weight 25-30% over separate inner / outer panels with metal-frame construction, while providing a 20% reduction in part and assembly costs. Better aesthetics are also achieved with no additional finishing. | ||
| Finalist |
Chassis / Hardware - Entry 50 |
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Active Vacuum Booster Connecting Plunger |
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| OEM: | DaimlerChrysler | |
| Model: | Durango | |
| Model Year: | 2006 | |
| System Supplier: | Robert Bosch Corporation | |
| Molder / Processor: | NYX Fort Wayne | |
| Toolmaker: | NYX Fort Wayne | |
| Material Supplier: | Chevron Phillips Chemical Co. LP | |
| Generic Resin Type: | PPS | |
| Resin Trade Name: | Ryton | |
| Grade: | R4-200BK | |
| Summary: The active vacuum booster connecting plunger achieved a 79% weight reduction by replacing steel. Highly functional plastic design allows additional molded-in features while achieving a 5% cost reduction. The part must meet high load and wear-resistance requirements for life while maintaining tighter-than-industry-standard tolerances. | ||
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Chassis / Hardware - Entry 22 |
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Electric Parking Brake |
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| OEM: | Audi | |
| Model: | A6 | |
| Model Year: | 2004 | |
| System Supplier: | TRW | |
| Molder / Processor: | Oechsler | |
| Toolmaker: | Oechsler | |
| Material Supplier: | Ticona | |
| Generic Resin Type: | PPS | |
| Resin Trade Name: | Fortron | |
| Grade: | 1140L4 | |
| Summary: The electric-parking brake (EPB) system replaces mechanical parking brakes and the bulky mechanisms associated with them (e.g. hand levers, foot pedals, cable mechanisms, etc.). It features drive-away assist for hill starts, and emergency braking via the vehicle stability-control system, providing more driver comfort and convenience. | ||
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Chassis / Hardware - Entry 23 |
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Truck Tire Tray |
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| OEM: | Honda | |
| Model: | Ridgeline | |
| Model Year: | 2005 | |
| System Supplier: | Ventra Plastics | |
| Molder / Processor: | Ventra Plastics | |
| Toolmaker: | Concours Mold Inc. | |
| Material Supplier: | Ticona | |
| Generic Resin Type: | GF PP | |
| Resin Trade Name: | Celstran | |
| Grade: | PP-GF30-03 | |
| Summary: The use of long-fiber-reinforced thermoplastic (LFRT) polypropylene (PP) instead of thermoset sheet-molding compound (SMC) provides a unique balance of stiffness, strength, and toughness at both high and low temperature extremes, as well as a 30% cost improvement. The unique concealed-tray design provides additional trunk space with improved security, while a 30 - 35% weight savings improves fuel economy. | ||
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Chassis / Hardware - Entry 39 |
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Power-Steering Reservoir Pump |
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| OEM: | Ford | |
| Model: | Focus | |
| Model Year: | 2006 | |
| System Supplier: | Plastech | |
| Molder / Processor: | Plastech Port Huron | |
| Toolmaker: | Plastech | |
| Material Supplier: | Rhodia | |
| Generic Resin Type: | PA 66 | |
| Resin Trade Name: | N/A | |
| Grade: | SSD330 | |
| Summary: First considered to be “non-manufacturable," this power-steering reservoir has been relocated away from the exhaust while using fewer hydraulic-line connections, requiring 35% less power-steering oil, and reducing warranty costs. Interior noise has also been reduced, a 1.5 lb / vehicle weight savings achieved, and there is a cost savings of $10.33 / vehicle. | ||
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Chassis / Hardware - Entry 45 |
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Door Module |
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| OEM: | General Motors | |
| Model: | GMT201 | |
| Model Year: | 2005 | |
| System Supplier: | Delphi Corporation | |
| Molder / Processor: | Delphi Corporation | |
| Toolmaker: | M2M / Synergetic Group | |
| Material Supplier: | Adell Plastics | |
| Generic Resin Type: | 40% GF PP | |
| Resin Trade Name: | N/A | |
| Grade: | ER-38 BK | |
| Summary: With this door hardware module, higher cost, higher mass, glass-filled polycarbonate / polyethylene terephthalate (PC / PET) resin has been replaced by glass-filled polypropylene (GF PP). This particular grade of resin was developed to meet the application's requirements for high dimensional stability; high-temperature strength, creep, and fatigue properties; and grease resistance, while performing at lower cost and mass. Additionally, the material is recyclable, allowing for reuse of process scrap in the product and facilitating end-of-life recyclability. | ||
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Chassis / Hardware - Entry 59 |
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Engine Acoustic Belly Pan |
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| OEM: | DaimlerChrysler | |
| Model: | Jeep Liberty | |
| Model Year: | 2005 | |
| System Supplier: | BBi Enterprises | |
| Molder / Processor: | BBi/Jinyi Automotive | |
| Toolmaker: | BBi/Jinyi Automotive | |
| Material Supplier: | China Petrochemical | |
| Generic Resin Type: | HDPE | |
| Resin Trade Name: | N/A | |
| Grade: | 6070EA | |
| Summary: This application combines a noise-containment system with a molded plastic part. The requirements for developing a noise-containment device were complicated by lack of space between the engine, the front engine cradle, and the front skid plate. Containment and retention were managed despite all of these packaging challenges. The plastic part retains the noise-containment devices and conforms to the top side of the skid-plate package. | ||
