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| WINNER |
Materials - Entry 15 |
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Molded-in-Color Reactor TPO for Airbag Covers |
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| OEM: | General Motors | |
| Model: | Buick Lucerne | |
| Model Year: | 2006 | |
| System Supplier: | Autoliv | |
| Molder / Processor: | Key Plastics | |
| Toolmaker: | Key Plastics | |
| Material Supplier: | Basell Polyolefins | |
| Generic Resin Type: | TPO | |
| Resin Trade Name: | Hostacom | |
| Grade: | CA199P | |
| Summary: This new material is the first molded-in-color (MIC) reactor TPO with excellent cold-temperature impact resistance for Class-A side-airbag covers. The new TPO meets all related OEM specifications and offers significant cost savings vs. conventional painted covers. | ||
| Finalist |
Materials - Entry 14 |
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PC-Si Copolymer For Active Airbag Upper |
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| OEM: | General Motors | |
| Model: | Cadillac DTS | |
| Model Year: | 2006 | |
| System Supplier: | Lear Corporation | |
| Molder / Processor: | Lear Corporation | |
| Toolmaker: | Hi-Tech Mold | |
| Material Supplier: | GE Advanced Materials | |
| Generic Resin Type: | PC-Si Copolymer | |
| Resin Trade Name: | Lexan | |
| Grade: | EXL1414H | |
| Summary: A new PC-silicone copolymer was developed to provide extreme low-temperature ductility, which enables robust performance in rigid passenger airbag panels at -30oC. The material's combination of rigidity, heat resistance, and low-temperature performance provides cost reductions in passenger airbag (PAB) systems through the elimination of additional strengthening components. | ||
| Finalist |
Materials - Entry 36 |
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Cross-Linked Expanded Polyethylene Seat Halo |
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| OEM: | General Motors | |
| Model: | Chevrolet Impala | |
| Model Year: | 2006 | |
| System Supplier: | Lear Corporation | |
| Molder / Processor: | JSP International | |
| Toolmaker: | Schraml Metalworks | |
| Material Supplier: | JSP International | |
| Generic Resin Type: | xEPE | |
| Resin Trade Name: | Arpex | |
| Grade: | 4500 Series | |
| Summary: The seat halo is the comfort ring that surrounds the rear seat area and incorporates the headrest and bolsters as one complete part. Conventional materials such as PU foam typically require a wire for support, which is not required with xEPE. The xEPE material is soft, ductile, and reduces weight when compared to incumbent material systems. | ||
| Finalist |
Materials - Entry 57 |
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PP/PS/Nano Material for Heater Vent |
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| OEM: | Audi | |
| Model: | A3 | |
| Model Year: | 2005 | |
| System Supplier: | Dr. Haubitz | |
| Molder / Processor: | Dr. Haubitz | |
| Toolmaker: | N/A | |
| Material Supplier: | Putsch GmbH | |
| Generic Resin Type: | PP/PS | |
| Resin Trade Name: | Elan | |
| Grade: | XP | |
| Summary: This new material -- comprised of PP/PS and nanocomposite filler -- offers exceptionally low gloss (matte finish), very-good scratch resistance, and a mold shrinkage of less than 1%. This resin can replace painted interior styrenic materials at a 50% cost savings. Besides an aesthetically pleasing matte finish, this resin also offers a good surface feel, which is required for many interior parts. | ||
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Materials - Entry 13 |
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Lightweight Carbon-Fiber Rear Deck Assembly |
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| OEM: | Ford | |
| Model: | GT | |
| Model Year: | 2005 | |
| System Supplier: | Mayflower Vehicle Systems | |
| Molder / Processor: | Sparta | |
| Toolmaker: | Coast Composites Inc. | |
| Material Supplier: | Toray Composites (America), Inc. | |
| Generic Resin Type: | Epoxy | |
| Resin Trade Name: | G83C | |
| Grade: | Torayca T600SC-24K | |
| Summary: The ultra-lightweight epoxy / carbon-fiber rear deck assembly significantly reduces weight vs. traditional metal systems. By adhesively bonding the carbon fiber / aluminum assembly, the galvanic-corrosion potential at attachment points is eliminated. Weight savings are in the range of 50 - 75% when compared to all-metal systems. | ||
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Materials - Entry 16 |
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Molded-in-Color Metallic Shifter Knob |
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| OEM: | Ford | |
| Model: | F-150 | |
| Model Year: | 2005 | |
| System Supplier: | Dura Automotive | |
| Molder / Processor: | Wright Plastics | |
| Toolmaker: | Mold Tooling Systems | |
| Material Supplier: | GE Advanced Materials | |
| Generic Resin Type: | ASA/PC | |
| Resin Trade Name: | Geloy | |
| Grade: | FXW751SK | |
| Summary: This molded-in-color (MIC, metallic-appearance shifter knob eliminated the need for paint, saving more than $1 / vehicle. The knob is made of a new MIC, UV-stabilized, acrylonitrile styrene acrylate (ASA) / polycarbonate (PC) grade with metallic flake. | ||
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Materials - Entry 52 |
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Carbon-Fiber Wheelhouse Assembly |
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| OEM: | General Motors | |
| Model: | Z06 Corvette | |
| Model Year: | 2006 | |
| System Supplier: | Molded Fiber Glass | |
| Molder / Processor: | Premier Molding Company | |
| Toolmaker: | Penco Tool | |
| Material Supplier: | MFG Research | |
| Generic Resin Type: | Unsaturated Polyester | |
| Resin Trade Name: | Ashland | |
| Grade: | N/A | |
| Summary: This wheelhouse assembly uses a low-density carbon-fiber / unsaturated polyester material that saved over 25% in weight vs. metal assemblies. The carbon-fiber prepreg was formulated to run on standard compression tooling at normal production rates. | ||
