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WINNER |
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(click on the picture to see a larger illustration - it opens in a new window, close that window to return here) |
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| Description: |
Composite Assist Step |
Model: |
Trailblazer / Envoy |
| OEM: |
General Motors |
Model Year: | 2007 |
| System Supplier: |
Mytox, Magna Decoma |
Generic Resin Type: |
PP Long Glass Fiber |
| Molder/Processor: |
Mytox, Magna Decoma |
Resin Trade Name: |
Myplas 40 |
| Toolmaker: |
N/A |
Grade: |
Myplas 40 |
| Material Supplier: | Mytox, Magna Decoma | Other Innovative Features: | Part consolidation: Components (3 brackets / fasteners, steel structure, TPO top cover) of running board designed into one piece running board. Plastic material replaced steel for structural application. |
| Most Innovative Feature: |
The innovation in design (structural ribs) and material (a long glass fiber PP) allowed for a running board to withstand higher loads and lower deflections at operating temperatures required by GM. Existing competitor plastic running boards in a one piece design would not satisfy GM requirements. |
Forming Process: |
A modified 2 stage injection molded process. |
| Weight Savings: |
Vehicle mass savings for GMT360 running boards were 28 pounds per vehicle. A 50% mass reduction compared to previous metal design. |
First Time Process Used? | No |
| Cost Savings: |
Direct cost savings in excess of $19.00 per vehicle. |
Previous Process: |
Metal formed understructure. Injection molded top cover. Metal formed brackets. |
| Cost Avoidance: |
Reduced assembly complexity and total cycle time of the running board (5 parts into 1). Mold in brackets eliminated fasteners. |
Transferable to Other Vehicles: |
Yes, this product technology is being applied to many vehicle lines. |
| Benefits to Consumer: | |||
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Yes. Lower weight and aerodynamics improved fuel economy. Eliminated squeak & rattle noise. Improved corrosion resistance. |
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| Method Comments: | |||
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MYPLAS 40 is a PP long glass fiber weatherable material that was specially developed to meet GM Material requirements of GMP.PP-PIM.002 for this running board. |
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| Innovations/Improvements: | |||
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No special tooling innovations required to produce this part. |
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| Safety Improvements: | |||
| N/A |
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| Environmental Comments: | |||
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Material is recyclable. Offers better fuel economy. |
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| Additional Comments: | |||
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GM running boards have a higher structural load requirement than other OEMs. Existing designs of one piece plastic running boards would not meet the GM structural part performance requirements. The design innovations of the type and location of the ribs were critical to allow GM to meet the higher load requirements of the running board. |
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| Summary: | |||
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Innovation in rib design and use of weatherable material enabled this 1-piece running board to withstands higher loads with lower deflections than the 5-piece steel and plastic assembly it replaced. It is produced in a 2-stage injection molding process and provides a 50% mass reduction and a direct cost savings in excess of $19 USD / vehicle, while also lowering assembly complexity, improving aerodynamics, eliminating corrosion, and quieting buzz/squeak/rattle noise. |
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