Published 11/2/2023

SPE Automotive Division names finalists for 52nd Automotive Innovation Awards

Finalists display a variety of plastics and composites innovations. Winners will be announced Nov. 8, 2023, during the 52nd SPE Automotive Innovation Awards Gala.

Automotive

Katie Leesemann, Former Editorial Assistant, Gardner Business Media

Aftermarket and Limited Edition/Specialty Vehicles

Hybrid battery interconnect board. Photo credit, all images: SPE Automotive Division

Hybrid Battery Interconnect Board

OEM Make & Model: 2024 General Motors Co. Chevrolet Corvette E-Ray
Tier Supplier/Processor: Sun Microstamping Technologies
Material Supplier/Toolmaker: BASF Corp. / Sun Microstamping Technologies
Material/Process: Ultramid B3UG4 PA6 / vertical clamp parting line injection rotary molded – insert overmolding

The patented hybrid battery interconnect board features small and delicate metal current collectors, bus bars and sensing lines in a compact design to fit in limited packaging space. The 20% glass fiber-reinforced PA6 grade was selected for its ability to offer high levels of functional integration in limited space plus be compatible with snap-fits, heat staking, ultrasonic welding and adhesive bonding. The material also is heat stabilized and flame retardant. Laminated core-block inserts are used in rotary injection tooling for venting and to control stampings during overmolding.

Plastic Oil Cooling Lines

OEM Make & Model: 2024 General Motors Co. Chevrolet Corvette E-Ray
Tier Supplier/Processor: Automotive Veritas de México, S.A. de C.V.
Material Supplier/Toolmaker: EMS-Grivory / Automotive Veritas de México, S.A. de C.V.
Material/Process: Grilamid XE 3975 PA6 and Grilamid 2S25WHLX / 10-HIP / plastic pipe oven forming

Replacing aluminum with flexible rubber hose, an injected plastic fitting is laser welded to plastic tubing and assembled to an aluminum block with a steel plate for structural rigidity while permitting the current system interfaces to be used in limited packaging space. Mass was reduced by 30% and direct cost by 23% while improving the oil cooling circuit pressure drop by 51% versus benchmark technology. The neat, semi-flexible PA6/10 polymer contains 62% bio-based monomer and offers good cold-temperature impact, chemical resistance and short-term temperature peaks.

Swappable Battery Cell Holder

OEM Make & Model: 2024 Sun Mobility Pvt. Ltd. GEN 2 Ph II
Tier Supplier/Processor: Sun Mobility Pvt. Ltd. / Sanko Gosei
Material Supplier/Toolmaker: SABIC / Sanko Gosei
Material/Process: Stamax 30YH570 FR PP 30% LGF / injection molding

The swappable battery cell holder meets stringent regulatory standards and requirements. It features an injection molded long fiber thermoplastic (LFT) polypropylene (PP) with an intumescent, halogen-free, flame-retardant package selected for safety, mechanical performance and compliance with environmental regulations.

Body Exterior

Flush sealing system.

Composite Cross-Members

OEM Make & Model: 2022 Hyundai Motor Group Genesis GV70 and G80
Tier Supplier/Processor: Sungwoo Hitech / Shinsung Composite Materials
Material Supplier/Toolmaker: Hyosung Advanced Materials Corp. /Kukdo Chemical Co. Ltd./ NA
Material/Process: KFR5121& KFH9581LV epoxy / injection box-based pultrusion

A novel hybrid pultrusion process can cost-effectively produce up to 20 million load-bearing and E-coat-capable structural composite beams annually thanks to a fully automated process. Beams provide the primary load path to pass IIHS side and pole impact tests, protecting occupants and on onboard battery packs while achieving a 30% increase in impact resistance versus roll-formed steel. An injection box added to the pultrusion line infuses high-performance epoxy into unidirectional carbon fiber and woven fiberglass reinforcement, reducing mass/vehicle by 12 kilograms and tool cost by 30% versus metallic benchmarks. Beams are attached to the body-in-white (BIW) via structural adhesives and blind rivets.

Flush Sealing System

OEM Make & Model: 2024 NIO Ltd. NIO EC7, ES8, EC6 and ES6
Tier Supplier/Processor: Cooper Standard
Material Supplier/Toolmaker: Celanese Corp. and Shin-Etsu & EMS Grivory / Cooper Standard
Material /Process: Santoprene 123-50W175 TPV and Exelast SX553 (TPO) and Grilon TSG-50/4 (PA66+PA6,GF50) rails: Co-extrusion with overmolding for finishing ends, sliders: Injection molding

This patented sealing system enables separation of the glass guidance rails/sliders from the weatherstrip/seal on framed doors, permitting improved aesthetics similar to frameless doors at lower mass, better noise/vibration/harshness (NVH), reduced complexity and faster assembly. The cost-neutral system also permits window regulators on framed doors and some competitive flush-glazing options to be converted from dual to single rails for both front and rear doors. A combination of injection molding and extrusion are used to produce the thermoplastic system, which maintains ±0.1 millimeter tolerances. Virtual validation technology was used to eliminate the need for physical prototypes.

Thermoplastic Splitgate

OEM Make & Model: 2023 Rivian LLC Rivian R1S
Tier Supplier/Processor: Magna International
Material Supplier/Toolmaker: Advanced Composites Inc. / Tycos Tool & Die Co.
Material/Process: LGF-PP and TPO / injection molding

This is reported to be the world’s first all-thermoplastic split gate rear-closure system, which is delivered to the assembly line as a ready-to-install module. The complex, deep draw (>80 millimeter) design offers improved perceived quality at lower mass, NVH and cost versus metals, and is offered in a two-tone execution. By commonizing grades between the liftgate and the benchgate and focusing on sustainability, parts were reduced from nine to three, and only two materials are used (injection molded LFT-PP and thermoplastic olefin/TPO). The CHMSL and tail lamps were carried over from the pickup model.

Uniformly Lit Animated Tail Lamps

OEM Make & Model: 2023 General Motors Co. GMC Sierra and Chevrolet Silverado HD 2500/3500
Tier Supplier/Processor: Magna Lighting
Material Supplier/Toolmaker: Trinseo PLC / DBM Reflex
Material /Process: Plexiglass V825-100 PMMA / injection molding

Key to the crisp and uniformly lit appearance of these animated taillamps are micro-optical features on injection molded light guides produced via a specialized manufacturing technique. Using an algorithm, the process starts by generating a pseudo-randomized topology that is machined into a master that is then used to create an electroform nickel insert. The technology produces a smooth appearance with far fewer LEDs, eliminates hot spots from point light sources and permits crisper animation in tighter packaging depths versus traditional approaches.

Body Interior

Foamed door panel.

Back-Lit Wrapped Interior Trim

OEM Make & Model: 2023 SAIC General Motor Corp. Ltd. Buick Century
Tier Supplier/Processor: Yanfeng Automotive Interior Systems Co. Ltd.
Material Supplier/Toolmaker: Benecke Changshun Auto Trim (Zhangjiagang) Co. Ltd. / Yanfeng Automotive Interior Systems Co. Ltd
Material/Process: BB2CAC-ZZZZ TPO / translucent TPO extrusion molding

This interior trim lighting system is hidden until lit, yet provides these backlit wrapped interior parts with the feel of leather and vibrant special lighting effects in a limited design space. Key to the execution is a transluscent TPO extrusion molding process and a precise ink coating layer between surface and translucent 3D mesh backing fabric. Light transmission and emitted colors are controlled by colorant concentration. Versus TPE injection molding and PVC with punched holes filled with adhesive, cost and weight are reduced while recyclability is improved versus PVC.

Foamed Door Panel

OEM Make & Model: 2024 Renault Group Renault Espace
Tier Supplier/Processor: Antolin
Material Supplier/Toolmaker: LyondellBasell and Avient Corp. / Antolin
Material/Process: TPO / chemical foaming injection molding with core-back molding

Up to a 25% weight reduction with no loss of stiffness and 25% CO₂ reduction were achieved in this MIC, Class A TPO door panel (carrier + map pocket) by combining core-back molding and chemical foaming in a multicavity tool with significant volumetric differences between cavities. A key enabler was use of a proprietary pressure regulation system with in-mold sensors, a TPO material specially developed for core-back/foaming and a chemical foaming technology that achieved uniform and well-defined cell structure in both parts.

Mega Bin / Frunk

OEM Make & Model: 2024 Ford Motor Co. Ford F-150 Lightning
Tier Supplier/Processor: Cascade Engineering
Material Supplier/Toolmaker: Celanese Corp. / Commercial Tool Group
Material/Process: Celstran PP-GF40 AD3004 (PP-LFT 40%) / injection molding

By converting from compression molded painted sheet molding compound (SMC) to injection molded MIC LFT-PP to produce this large Class A composite frunk — currently the industry’s largest — mass was reduced 48%, productivity was increased owing to a 37% cycle time reduction, the cost and environmental burden of paint were eliminated, seal interfaces were improved, secondary routering of holes is no longer needed and the frunk is fully recyclable at end of life. A 4,000-ton injection press and a tool equipped with a 16-drop hot runner system are used to mold parts.

Electric & Autonomous Vehicle Systems

Battery disconnect unit.

Battery Disconnect Unit

OEM Make & Model: 2023 General Motors Co. GMC Hummer EV
Tier Supplier/Processor: Lear Corp.
Material Supplier/Toolmaker: BASF Corp. / Lear Corp.
Material /Process: Ultramid 66 H2 G25 V0KB1 and Ultradur B4450G5 HR / injection molding

Two BDUs have been integrated into a single system supporting two 400-volt systems, which enable fast and safe recharging of electric vehicles (EVs) and disconnects power in an over-current situation to protect passengers. The meter-long parts feature a complex design that offers improved thermal management and reduced component mass. Two UL94 V0 halogen-free materials — one with very high CTI — replaced die-cast aluminum while maintaining improved physical properties and ease of processing. Complex simulation and process optimization were also key to success.

Interconnect Board

OEM Make & Model: 2023 General Motors Co. Cadillac Lyriq and GMC Hummer EV
Tier Supplier/Processor: Korea Electric Terminal Co. Ltd.
Material Supplier/Toolmaker: LG Chem Ltd./ NA
Material /Process: Lumid GN2251BF PA66-GF25 / injection molding

This patented interconnect board (ICB) design supports, cools and isolates cell tabs/busbars, provides support and structure to the module between the top cover and cold plates and aids assembly by guiding, supporting and constraining cell tabs. The overmolded busbar design, which reduces copper use by approximately 25%, enables cooling through the frames from the cold plate. Honeycomb and rib features on the back reduce mass, increase clearance to cells, improving structure, especially during critical manufacturing processes, and contribute to finger-proofing requirements. Additionally, the hinged ICB ships flat, reducing shipping space by 78%, then folds for assembly.

Battery Module Component

OEM Make & Model: 2023 Hyundai Motor Group Ioniq 6
Tier Supplier/Processor: Hyundai Mobis Co. Ltd./ Infac Corp.
Material Supplier/Toolmaker: SABIC Korea / NA
Material /Process: SABIC PPc H1030 PP-SGF30 / injection molding

Use of a 30% GR/PP material with intumescent fire-retardant (FR) package reduces weight 10% and cost 20% while improving fire safety versus FR 30% GR/PA6. This is also the first thermoplastic to pass China’s GB/T 41467.3-2015 fire safety regulation for EVs surviving 5 minutes at 1,000°C. Improved flow properties versus PA6 permitted higher cavitation tooling to be used, doubling productivity in the same cycle time, while also lowering molding temperatures for energy and CO₂ improvements. Versus metals, mass reduction of 18 kilograms/vehicle is achieved. The design also features an integral overmolded busbar.

Materials

Battery module side plates.

Console Hinge Bracket

OEM Make & Model: 2024 Ford Motor Co. Lincoln Corsair
Tier Supplier/Processor: IAC Group
Material Supplier/Toolmaker: The Materials Group / NA
Material/Process: Optilon N6 50BFM HSL PA6 / injection molding

This high-fiber, MIC, injection molded, Class A console hinge bracket features more sustainable basalt rather than E-glass fiber reinforcement. No reduction in performance or durability was seen in these color-matched 50% basalt/PA6 parts, but the switch addressed fiberglass shortages, reduced costs and improved CO₂ footprint.

Battery Module Side Plates

OEM Make & Model: 2024 General Motors Co. Chevrolet Corvette E-Ray
Tier Supplier/Processor: Novares Group
Material Supplier/Toolmaker: RTP Co. / Liberty Molds Inc.
Material/Process: RTP 299 K X 138337 E Black / injection molding

By replacing metals with RTP 299 K X 138337 E Black Para material to injection mold the side plates for this battery module, extremely flat parts with high dimensional accuracy, stiffness and strength were achieved in a complex geometry. The high-modulus, creep-resistant FR polymer eliminated the need for compression limiters and electrical isolation films, yet withstood extreme pressures from cell expansion and met all mechanical requirements. Additionally, four components were reduced to one and many functional features were incorporated in the patented side plates that would not have been possible in metals. Mass was reduced by 37% and cost by 55%.

Roof Vent Cover

OEM Make & Model: 2023 Rivian LLC RSV / RCV
Tier Supplier/Processor: SRG Global
Material Supplier/Toolmaker: SABIC / NA
Material /Process: LEXAN SLX2271T PC / injection molding

This high-gloss, MIC PC block copolymer with self-healing capabilities offers better UV stability, scratch resistance and thermal performance than painted ABS or PC/ABS, while reducing cost significantly owing to elimination of paint. No tooling changes were required, the CO₂ footprint was reduced, parts are now recyclable at end of life (owing to elimination of paint) and multiple color options are available.

Processing/Assembly/Enabling Technology

Console structural carrier tooling.

Seat Module

OEM Make & Model: 2024 Toyota Motor Corp. Toyota Grand Highlander
Tier Supplier/Processor: Hi-Lex Corp.
Material Supplier/Toolmaker: NA / Hi-Lex Corp.
Material/Process: NA / injection molding

This patented injection molded module for seats incorporates both temporary and permanent holding features to control cables and dramatically reduce both components and labor at the seat manufacturer. Cables are delivered to the Tier 1 pre-routed on the module plate, eliminating the brackets, cable ties and clips typically used to control seat cables, and greatly reducing labor for an assembly operator. The module also reduces rework and scrap due to cable misalignments. Additionally, lever pull effort for consumers is reduced because direct cable routing enables use of shorter cables.

Laser Welded xEV Spray Bars

OEM Make & Model: 2023 Ford Motor Co. Ford Edge
Tier Supplier/Processor: Nifco America Corp. / NA
Material Supplier/Toolmaker: Celanese Corp. / NA
Material /Process: Zytel 45HSB PA 6/6 / injection molding and laser welding

Moving from drilled metal to molded plastic tubes on spray bars can reduce mass and cost and reduce contamination concerns involving the presence of metal shavings from drilling operations. To create an enclosed structure with the holes needed to spray fluid via injection molding, parts must be molded in two complex, contoured halves and joined. The cleanest joining process proved to be laser welding. The high-flow, heat-stabilized PA6/6 grade was selected for its high thermal resistance, low contamination, consistent quality and resistance to automatic transmission fluid.

Compressor Housing

OEM Make & Model: 2022 General Motors Co. Cruise Origin
Tier Supplier/Processor: HP Inc. & Carbon Inc. / GKN Additive (Forecast3D)
Material Supplier/Toolmaker: HP Inc. & Carbon Inc./NA
Material /Process: HP PA12 HR and Carbon EPX82 epoxy / HP MJF 5100 Series + Carbon M2

To meet application specifications and tight timing requirements, two different polymer additive manufacturing processes (MJF and SLA) and two different polymers (PA12 and epoxy) were combined to produce the compressor housing for this low-volume, autonomous vehicle. MJF offered high throughput and cost effectiveness for the bulk of the compressor housing while SLA offered higher dimensional tolerances and smoother surface finish on the connector, which facilitated passing USCAR push/pull requirements. By using each process’ strength and bonding parts together, cost and performance were optimized, tooling was eliminated and program delays were avoided.

Battery Module Structure

OEM Make & Model: 2024 General Motors Co. Chevrolet Corvette E-Ray
Tier Supplier/Processor: General Motors Co. / Novares Group
Material Supplier/Toolmaker: RTP Co. and Solvay SA / Liberty Molds Inc.
Material /Process: RTP 299 KX133837E Para and Amodel A-1145 HS BK 324 PPA / injection molding

This all-thermoplastic battery structure combines two side plates and 45 repeating spacers bolted together to hold pouch-style batteries. The patented, volumetrically efficient design withstands high cell expansion forces during battery use while eliminating the need for 55 compression limiters plus isolation countermeasures necessary with metals. Side plates are injection molded with 50% GR/Para while spacers are injection molded with 45% GR/PPA. Both materials required high molding precision, dimensional accuracy, flame retardance and the ability to integrate a variety of functional features that facilitate assembly. Versus aluminum, both mass and cost are reduced.

Console Structural Carrier Tooling

OEM Make & Model: 2024 General Motors Co. Cadillac Lyriq
Tier Supplier/Processor: ABC Technologies Inc.
Material Supplier/Toolmaker: Celanese Corp. / Integrity Tool and Mold Inc.
Material/Process: Celstran PP-GF40-0453 (40% LFT PP) / injection molding

Tight packaging space and the space for an HVAC outlet in the console meant a traditional through-pin-type hinge could not be used on the armrest to keep it latched during a crash. A friction hinge with inertial lock — previously only used in the furniture industry — solved the problem, but required unique tooling innovation to be feasible. The triple-action, two-stage slide featuring a horn-pin driven slide with collapsible lifters on top of a hydraulic main bottom slide was developed, enabling direct edge gating on top of the slide to optimize filling conditions.

Safety

Pyrophobic terminal covers.

Battery Disconnect Unit Finger-Safe Covers

OEM Make & Model: 2023 General Motors Co. GMC Hummer
Tier Supplier/Processor: Grand Traverse Plastics Corp.
Material Supplier/Toolmaker: RTP Co. / Quest Industries Inc.
Material/Process: RTP 199 X 137777 D S-481951 safety orange FR PP / injection molding

To increase safety and prevent accidental contact with high-voltage connections during assembly and service, and to reduce warpage that could cause manufacturing concerns, the component was redesigned to include alternating coring patterns along the top and bottom surfaces, which reduced warpage by 81%. The component also features slots to permit use of forward-looking infrared (FLIR) cameras to view busbar connections below the component surface. The FR UL94 V0 material is supplied in safety orange.

Intumescent Terminal Covers

OEM Make & Model: 2023 General Motors Co. Cadillac Lyriq and GMC Hummer
Tier Supplier/Processor: Auto-Kabel Group/ Molded Precision Components
Material Supplier/Toolmaker: Pyrophobic Systems Ltd. / NA
Material/Process: Lithium Prevent 200 PVC / injection molding

A formulated flexible and intumescent PVC is designed to prevent arcing during thermal runaway events in high-voltage EV batteries. The high-temperature, high-voltage insulator is used to injection mold various terminal caps and barriers. Safety is increased during thermal runaway since the material maintains high dielectric strength, reducing arcing risk and ignition of gases, and forms a structured char barrier, helping reduce spread of fire from one module to another.

PAB Hybrid “U/Y” Door

OEM Make & Model: 2024 Ford Motor Co. Ford Mustang
Tier Supplier/Processor: Detroit Manufacturing Systems LLC / Forvia
Material Supplier/Toolmaker: Mitsubishi Chemical Performance Polymers Inc. / King Mold
Material /Process: Thermorun TT850N TPE / injection molding, vibration welding, IMGL, laser score

Owing to the vehicle’s shallow sloped windshield, it was necessary to modify the typical U or Y design on the PAB chute door and hinge design to facilitate proper airbag deployment and prevent inadvertent cracking of the windshield. A combination of injection molding, vibration welding, in-mold grain lamination and laser scoring are used to create a modified U/Y door/hinge design that opens as a U shape and then folds during windshield contact. After opening, momentum of the door is slowed via the hinge design.

Sustainability

Eco-friendly cable control.

Basalt Fiber-Reinforced ADAS Bracket

OEM Make & Model: 2024 Ford Motor Co. Ford F-150
Tier Supplier/Processor: Yazaki Corp. / HellermannTyton
Material Supplier/Toolmaker: The Materials Group / HS Mold Ltd.
Material/Process: Optilon N6-30B HSBK 30% basalt fiber-reinforced PA6 / injection molding

By replacing E-glass with basalt fiber in this injection molded ADAS bracket, which also contained 60% PIR PA6, cost and weight were neutral, the part met all performance requirements, no tooling changes were needed, but a CO₂ reduction of 74% was achieved and 180,000 kilograms of material annually is kept from landfills. The drop-in change is more sustainable, addresses issues with glass shortage and provides the same performance as virgin material.

Bracket from Recycled BMC

OEM Make & Model: 2023 General Motors Co. Chevrolet Silverado LD
Tier Supplier/Processor: Valeo Lighting Systems / Techniplas
Material Supplier/Toolmaker: LyondellBasell / Chicago Mold Engineering Co. Inc.
Material/Process: Dura 304 UP BMC / injection molding

Replacing magnesium with unsaturated polyester BMC yielded structural brackets meeting high dimensional requirements at comparable or improved mechanical performance — especially toughness. The bracket was made more sustainable with inclusion of 6% PIR PMMA and 5% PIR BMC scrap, which replaced calcium carbonate filler. It took 2 years of work to develop the process to recover and reclaim thermoset BMC scrap and reuse it in new parts with a lower CO₂ footprint. Key to the success of the program were grinding, sizing and formulation strategies. No tooling changes were required versus virgin BMC.

One-Piece Thermoplastic Frunk

OEM Make & Model: 2024 Ford Motor Co. Ford Mustang Mach E
Tier Supplier/Processor: IAC Group
Material Supplier/Toolmaker: Advanced Composites Inc. / HS Inc.
Material/Process: ADX8327 20% PCR TPO / injection molding

This is the first time a 20% PCR recycled material has been used in a color-matched, MIC, Class A structural funk application. Versus virgin TPO, the more sustainable grade lowered density slightly and offered better impact at -15°C. Concurrent redesign reduced component count from six to one, including eliminating two metal brackets, saving 3 kilograms of mass, increasing cargo volume and functionality, improving water management, reducing cost and labor and saving an estimated 1,125 tons of CO₂ annually. PCR content is sourced from yogurt cups and packaging materials.

Eco-Friendly Cable Control

OEM Make & Model: 2024 Ford Motor Co. Ford Mustang
Tier Supplier/Processor: Aptiv PLC / HellermannTyton
Material Supplier/Toolmaker: Ascend Performance Materials / NA
Material/Process: Redefyne IAI2H BK0858 PA66 / injection molding

This is reported to be the first broad-scale shift from virgin to PIR PA66 in cable management parts, a drop-in-change offering comparable performance, aesthetics and processing at lower cost and 35% lower carbon footprint without any part design or tooling changes. Although the parts are small, they are produced in high-cavitation injection tooling and offer best-in-class mechanical, thermal and chemical performance. In just the first year, the change removed 138,000 kilograms of CO₂ and saved 70,000 kilograms of coal and 144 billion barrels of crude oil from being used.