Direct Metalized High Heat Headlamp Bezel

OEM: Ford Model: Lincoln Navigator
Model Year: 2007 Molder/Processor: ACH Holdings Limited
System Supplier: ACH Holdings Limited Molder Contact: Craig Pack
System Contact: Sunil Dalal/Schickle Molder Phone: 419 627-3498
System Phone: 313-255-5970 Material Supplier: DuPont Automotive
Toolmaker: BTM Material Contact: Steven Fecanin
Toolmaker Contact: Jesse Garant Material Phone: 317-848-5448
Toolmaker Phone: 519 980 4749 Generic Resin Type: PBT
OEM Permission: Yes Grade: CE2548 GY740
OEM Engineer: Lisa Hohmann Nominator: Carole Davies
OEM Title: Sr. Project Engineer Nominator's Company: DuPont
OEM Phone: 313-805-0676 Nominator's Address: 950 Stevenson Hwy.
Troy, MI 48083
Forming Process: Injection Molding Nominator's Phone: 248-583-8112
First Time Process Used? Yes Nominator's Email: carole.a.davies@usa.dupont.com
Weight Savings: Wall sections thinner than possible with amorphous resins. New designs are larger than predecessors. Generally new bezels can be 30% thinner than amorphous resin. Cost Savings: Generates up to 40% materials savings vs more expensive alternate materials.
    Cost Avoidance: Regrind can be used at 25%(not typical). Highflow allows walls sections designed 30% thinner.
       
Summary: This is the first headlamp bezel launched in North America with a PBT crystalline plastic that can be directly metalized without use of a base coat. The team developed the resin, tooling and processing expertise necessary to create an as-molded, high-gloss, Class-A surface for these decorative parts. Additionally, their 30% thinner wall section leads to as much as a 40% material cost savings.
   
Most Innovative Feature: First headlamp bezel launched in NA with PBT crystalline plastics that can be directly metalized without base coat.
   
Other Innovative Features: The team developed the resin, tooling and processing expertise necessary to create a Class A surface for these decorative parts.
 
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