SPE names Automotive Innovation Award winners

Livonia, Mich. — Automakers, suppliers, engineers and plastics experts once again gathered to celebrate a handful of industry firsts and lightweight parts applications Nov. 7 at the automotive division of the Society of Plastics Engineers' 48th annual Automotive Innovation Awards Gala.

Nine category winners were announced as well as one grand winner. This year's Hall of Fame award and Lifetime Achievement Award winners were also honored.

Ford Motor Co. took home the top award for its entry in the powertrain category: the all-plastic vacuum generation system for brake assist on the 2017 F-150 pickup. The thermoplastic part achieves a 40 percent weight reduction and a 25 percent cost savings over current pump systems. Dayco Products LLC is the Tier 1 supplier. MacLean-Fogg Component Solutions and Engineering Plastics Co. are the processors. Materials are from DowDuPont Inc.

SPE honored Honda Motor Co. Ltd. with this year's Hall of Fame award for what the society said is the first injection molded thermoplastic rear energy absorber for a vehicle bumper system. The polycarbonate/polybutylene terephthalate energy absorber is on the 2003 Honda Element compact crossover. The PC/PBT part replaced an expanded polypropylene foam version, requiring less package space at a lower cost with better damageability performance.

As previously reported by Plastics News, Rose Ryntz, formerly the vice president of advanced development and material engineering at International Automotive Components Group, was recognized as the society's 2018 Lifetime Achievement Award winner. Ryntz resigned from her position at IAC Oct. 31.

Other category winners are as follows:

Fiat Chrysler Automobiles NV for the thermoplastic liftgate on the 2019 Jeep Cherokee. The thermoplastic liftgate replaces the steel design and enables a 28 percent mass reduction in addition to a 50 percent tooling and capital investment savings.

The automaker said it is an industry-first use of conformal infrared welding behind the molded-in-color grain Class A surface. Magna International Inc. is the Tier 1 supplier, with materials from Trinseo SA and LyondellBassell NV. Tycos Tool & Die Co., a division of Magna Exteriors, supplies the tooling.

Ford for the integrated modular pelvic bolster on the 2018 Lincoln Navigator SUV. The application combines two side-impact bolster designs into one and integrates the part into the door trim map packet.

The consolidated design offers an estimated cost savings of $100,000 in tooling and a 10 percent weight reduction. Faurecia supplies the system, using polypropylene material from LyondellBassell. Roush Industries Inc. supplies the tooling.

Fiat Chrysler for the high-strength, self-tapping composite nut on the 2016 Chrysler Pacifica minivan. The composite nut has self-healing properties that allow it to maintain sufficient torque and clamp load even after being stripped.

Estimated cost savings are $3.25 per vehicle. ITW Deltar Fasteners supplies the system, using material from Asahi Kasei Corp. and tooling from Maple Mold Technologies Inc.

Ford for the use of sustainable hybrid composites on the 2018 Lincoln Continental luxury sedan. The automaker said the industry-first application of composites combining cellulose fiber from trees with long glass fiber in a polypropylene matrix results in a $2 million cost savings achieved by reducing weight by 24 percent and shortening cycle times by 20-40 percent.

Summit Polymers Inc. is the Tier 1 supplier and toolmaker. The composite materials are from Celanese and International Paper Co.

Hyundai Motor Co. for its use of electromagnetic interference shielding compounds developed for high-voltage junction box upper covers on the 2019 Nexo SUV.

The material — nylon with a hybrid conductive carbon filler from Hanwa Compound — replaces conventional die-cast aluminum for reduced weight and manufacturing costs. Yura Corp. supplies the system, with tooling from Hyundai.

Fiat Chrysler for the integrated tire carrier, rear camera and brake light assembly on the 2018 Jeep Wrangler. The hybrid composite technology uses magnesium injection molding for higher structural strength and reduced weight as well as polymer overmolding for better impact and corrosion resistance.

The new design also eliminates the need for a steel bracket. Grammer AG's Toledo Molding & Die Inc. is the Tier 1 supplier. Tooling is from Leggera Technologies LLC. DowDuPoint supplies the material.

Ford for the interlocking mechanism design for side impact on the 2019 Transit Connect van. The patent-pending design, which prevents the fracturing or separating of components that could cause sharp edges, replaces the need for metal bracket reinforcements. Faurecia is the Tier 1 supplier, with tooling from Meymol SL. Trinseo supplies the ABS material.

Ford for the window alignment fixture on the 2017 Mustang convertible. The 3D-printed fixture, made with a carbon-fiber-reinforced nylon from Stratasys Ltd., is 30 percent lighter and cheaper to produce than the traditional welded fixture. Stratasys supplies the system, material and tooling for the part.