| Summary: |
Replacement of filled SMA by low cost filled homopolymer PP
for an instrument panel lower carrier with no required changes in tooling or
automatic assembly equipment. Substantial cost savings from lower (43%)
resin cost. |
| Most Innovative Feature: |
Low cost filled homopolymer PP utilized in place of
traditional filled SMA. |
| Other Innovative Features: |
1. Linear shrink maintained so that all current injection
tooling used with no changes and automatic assembly equipment required only
minor adjustments. 2. Reduced the risk of BSR issues. 3. Achieved
physical properties necessary to meet part performance requirements. 4.
Utilized a commodity polyolefin resin. |
| What Forming Process? |
Injection Molding. |
| First Time Process Used: |
No. |
| Previous Process: |
Previous process was injection molding of filled SMA. |
| Tooling Innovations: |
Used the existing tooling and equipment. |
| New Material Developments: |
The key objectives were to obtain the modulus, creep
resistance and tool shrinkage of the SMA but with a significantly lower cost
PP material. |
| Weight Savings: |
None. |
| Cost Savings: |
Resin cost was reduced by 43%. (Part weighs ~5 lbs. at 1.6
million parts annually). |
| Cost Avoidance: |
Avoided potential changes to ten large injection tools by
matching linear shrinkage. |
| Direct Consumer Benefit: |
PP provides lower frequency response than previous SMA
material, lessening risk of BSR issues. |
| Translates to Other Vehicles?: |
Yes, we are considering other applications. |
| Safety Benefits: |
Meets the same part performance requirements as previous
material but at 43% cost reduction. |
| Environmental Benefits: |
Better recyclability potential than SMA. |
| Additional Comments: |
None. |
