GENEVA, SWITZERLAND -- DuPont Co. has developed an innovative automotive jounce bumper component to show how design, materials and processing can converge to deliver added performance and lower cost.
DuPont, worked with a team from Ossberger, to capitalize on the flexibility attributes of DuPont Hytrel thermoplastic elastomer and an Ossberger blow-molding technology to simplify the component from four pieces that require sub-assembly to a single piece. This significantly reduced cost, size and improved performance.
"Materials are critical in component design and the best results happen when the three primary phases in product development – design, materials and processing - converge," said Patrick Cazuc, automotive director Europe, and DuPont Performance Polymers.
DuPont worked on design, using non-linear Finite Element Analysis (FEA) techniques and specialist software, as well as processing, including rapid prototyping and laboratory testing at the DuPont European Technical Center. By using an Ossberger machine, the thickness profile was tightly controlled, facilitating optimum energy-absorbing properties with a maximum compression ratio.
Cazuc said: "The new jounce bumper is an example of DuPont listening to market needs and developing a superior solution, while providing all the necessary collaborative support needed to bring an idea from design to commercialization."