Automotive Engineering - January 2019 - 21

PLASTICS

MATERIALS FEATURE

spur tech innovations
The SPE
Innovation Awards
recognize vehicle
OEMs and their
supply chains for
novel material
developments
and applications.
by Ryan Gehm

ord Motor Co. took home top honors at the
48th SPE Automotive Innovation Awards
Competition, winning the Grand Award for its
Powertrain nomination, and claiming four other categories along with its suppliers. Fiat Chrysler
Automobiles (FCA) topped three categories and
Hyundai Motor Co. nabbed the Materials prize at the
largest recognition event in the automotive and plastics industries, held annually by the Automotive
Division of the Society of Plastics Engineers (SPE).
Automotive Engineering was again honored to participate on the Blue Ribbon Judges panel that reviews
the finalists in nine major materials-technology categories and votes on the winners in each.

Grand Award and Powertrain Award-2017
Ford F-150 vacuum generation system for
brake assist

Tier Supplier / Processor: Dayco Products / MacLeanFogg, Engineered Plastics Co.
Material Supplier / Toolmaker: DuPont Automotive /
Kaid Tool & Die
Material / Process: Delrin 73M30 POM+PTFE, Minion
520MP PA6 / injection molding
Airtight to 200 psi (13.8 bar) and leakproof following
infrared welding, the all-plastic vacuum generation system (VGS) consists of 10 components that work together to provide 20% better performance at higher elevations. The open/close valve actuation is accomplished
via two complementary resin systems acting in concert
to allow no "stick-slip" and no measurable wear after
2.5 million hot/cold test cycles. Injection molding allows
for very close tolerances of critical details necessary for
total system performance. The design achieved a 40%
AUTOMOTIVE ENGINEERING

Grand Award and Powertrain
winner: 2017 Ford F-150
vacuum generation system
for brake assist.

weight savings and a 25% cost savings compared to current pump systems. Tunable to various engine requirements, the VGS is already employed on four other Ford programs including the Taurus and Explorer,
according to a program engineer.

Additive Manufacturing Award-2017 Ford Mustang
Convertible window alignment fixture

Tier Supplier / Processor: Stratasys / Stratasys
Material Supplier / Toolmaker: Stratasys / Stratasys Direct Manufacturing
Material / Process: PA 12 35% short carbon fiber / fused deposition
modeling (FDM)
The 3D-printed fixture for the production floor is 30% lighter and
cheaper to produce compared to a traditional welded fixture. It took
only 50 hours to build the integrated fixture with handles and mounting brackets. Line of sight and ergonomics were improved significantly with the design, which allows for easier handling and precludes the need for a lift assist. The printed fixture also integrates
pneumatic control, eyelets for a stowage rack, trigger switch housing,
gage protector/deflector and pneumatic tubing retainers and switch
mounts. "Complexity doesn't cost you anything" in 3D printing, said
George Russell, Automotive Segment Leader at Stratasys.

Body Exterior Award-2019 Jeep Cherokee
thermoplastic liftgate

Tier Supplier / Processor: Magna International Inc. / Magna
Exteriors Belvidere
Material Supplier / Toolmaker: Trinseo & LyondellBasell / Tycos Tool & Die
Material / Process: DLGF 9411 & Hifax TYC TPO / injection molding
By replacing a steel liftgate with a new thermoplastic design, the engineering team enabled a 28% mass reduction and a 50% tooling and
capital investment savings through part integration and manufacturing
efficiency. The accelerated 18-month program, from sourcing to Job 1,
also resulted in NVH levels that exceeded target. A claimed industryfirst use of conformal infrared welding behind the molded-in-color
January 2019 21

Automotive Engineering - January 2019

Table of Contents for the Digital Edition of Automotive Engineering - January 2019