Automobile Exteriors

Exterior Applications of Plastics in Automotive

Rear lighting
Roof and superior hatchback trim

Front hood

Rear bumper

3-pieces front bumper

Front door panel Rear door panel
Possible Applications of Plastics in Automobile Exterior
Typical
Process Material
Resin/ filler options Weight
options Options
Exteriors Kg's
         
Bumper Systems      
Bumper Facia HLU UP CSM
(Front, Rear) RIM PU MF
  Compression UP SMC Roving
  Injection PP MF 10.00
    PBT CS
    PU MF
    Ionomer resin MF
    PTE MF
Bumper Beams Compression VE SMC Roving
4.60
(Front, Rear) GMT PP Mat Continuous
         
Suspension Systems        
Leaf Springs Pultrusion EP Continuous Roving 6.00
Body Panels and exterior Components        
Possible Applications of Plastics in Automobile Exterior
Pillar reinforcements (A,B,C) Compression UP SMC Roving
3.00
  IM/BMC UP CS
Exterior Body side parts R-RIM or RIM PU MF
15.00
  Injection PP MF
Door Sill Cover Injection TPU CS 2.00
Front Fender Injection PU CS
    PC-PBT  
4.00
    PA-PPE  
    PET CS
  RIM PU Mat Continuous  
  Compression UP SMC Roving  
Front & Rear Wheel Arch Injection PP MF
3.00
  RIM PU MF
Wheel Flares Injection PP MF
3.00
    PTE MF
Fuel Tank Protection GMT PP Mat Continuous 1.00
Hatch Back IM/BMC UP SMC Roving
  Compression UP SMC Roving 14.00
  RTM UP Mat Continuous
Possible Applications of Plastics in Automobile Exterior
Hood Compression UP SMC Roving
5.00
  RTM UP Mat Continuous
Under Floor Panel GMT PP Mat Continuous 2.00
Complete/Partial Body HLU UP CSM 150.00
Floor Compression UP SMC Roving 10.00
External Door Handles Injection PA CS
0.80
    PBT CS
Grilles Injection PP CS/MF
    MPPO  
    PA CS
    PBT CS 2.00

  IM/BMC UP CS
  Compression UP SMC Roving
  RIM PU CS
Possible Applications of Plastics in Automobile Exterior

Spoilers        
Front spoiler RIM PU MF
  Compression UP SMC Roving 2.00
  Injection PA CS
         
Rear Spoilers RIM PU MF
  Compression UP SMC Roving 2.50
  Injection PA CS
Mirror Housings Injection PA CS
0.80
    PBT CS
Fuel Tank Flap Injection PA CS 0.12
Wheel Cap Injection PA CS 2.00
Wheel Hub Cover Injection PA CS 1.50
Wind screen Wiper Support Injection PA CS
0.10
    PBT CS
Possible Applications of Plastics in Automobile Exterior

Headlamps Surrounds and Panels        

Headlamp Housing Compression UP SMC Roving

  Injection PA CS 0.20

    PP CS

Headlamp Reflector Injection UP CS

    PBT CS 1.00

  IM/BMC UP CS

Headlamp Lenses Injection PC   0.50

Headlamp support Injection PA CS 0.10

Tail Lamp Housing Injection ABS CS

0.80
  Compression UP SMC Roving
Possible Applications of Plastics in Automobile Exterior

Roof Components        
Hard Top Injection PP MF

  Compression UP SMC Roving 24.00

  HLU UP CSM

Sun Roof frame Compression UP SMC Roving

4.00
  Injection PA CS

Sun Roof Panel Compression UP SMC Roving

1.50
    PU CSM

Rear Door Roof extension Compression UP SMC Roving 7.00

Roof RTM UP Mat Continuous 15.00
Roof Appliques Injection PET CS 2.50
Roof Headers, Luggage supports Injection PC-PBT  
    PET CS 4.00
  R-RIM PU CS
 Front End Module Carrier
Front End Module Assembly Vehicle Assembly for Validation Tests
to specifications

Latch Assembly Integrated Air Duct

 Pedestrian Protection
Increased attention to pedestrian protection during medium velocity impacts,
lower repair costs upon low velocity impact, and front and rear end system
modularization presents a unique set of challenges in terms of design
consolidation, material mix, energy management, and assembly techniques

Head Impact
Package
space
reduction

Pelvis Impact

Modularization

Insurance and
low speed
impact
Leg Impact
Proposed Pedestrian Safety Tests
V = 40km/h, m = 2.5kg V = 40 km/h
V = 40km/h Ekin =154J M = 4.8 kg
Ekin < 700J HIC=1000 Ekin = 295 J
F = 5kN HIC=1000
MB = 300Nm

V =40km/h
m =13.4kg
E =825J
aknee = 150g
Øknee = 15°
Tknee = 6mm
 Complete Pedestrian Kinematics
Vehicle Knee joint Upper leg / pelvis Head contacts
contacts undergoes contact hood as
lower leg bending / shear hood front pedestrian rotates

Elapsed Impact Time

Design for the Leg Form
Leg Form Impact
α

d
Thermoplastic Door Concept 1
Thermoplastic Door Concept 2
 Thermoplastic Door Concept

Steel Profile

Aluminium
Extrusion Profil

Outer Panel: PC/PBT Inner Panel: PP TV

 Thermoplastic Rear Door Concept

Steel Profile

Aluminium
Extrusion Profil

Outer Panel: PC/PBT

Inner Panel: PP TV
 Thermoplastic Rear Door Concept
Tailgate Window
TAILGATE ASSEMBLY (PC )
- PP-LGF Inner
PP-GF Inner Trim Panel
- Xenoy Outer
- “NO Aluminium Frame”

Outer panel

PP-GF Inner
PP-GF Inner

Screws to PP-GF

Handle/logo

Outer panel