Plastics in Automotive Applications: Replacing Steel With ...

The automotive industry is undergoing a significant transformation driven by stringent Federal Corporate Average Fuel Economy (CAFE) Standards and increased awareness of the environmental repercussions stemming from fossil fuel usage. These demands necessitate a rethinking of vehicle design to optimize fuel efficiency.

To rise to these challenges, automotive producers are actively exploring methods to lessen the mass of vehicles without sacrificing performance or safety. The push for electric vehicles further necessitates weight reduction, as heavier vehicles experience constrained ranges between recharges.

One of the most promising approaches involves substituting steel with advanced thermoplastic composites. These materials can match the strength of steel while being substantially lighter, yielding multiple advantages. Below, we explore several prevalent plastic composite formulations that are emerging in modern automotive manufacturing:

Short Glass Fiber-Reinforced Plastics

Incorporating short glass fibers into plastics markedly enhances their strength, rigidity, and heat resistance. For automotive applications, these glass-reinforced polyamides and polyphthalamides are advantageous for achieving weight reduction, given their ability to comprise up to 50% glass fiber. This high content renders them ideal for critical engine parts, such as cylinder heads and cooling components. Automotive manufacturers are increasingly utilizing these materials to enhance the lifespan of various existing plastic components.

Long Glass Fiber-Reinforced Plastics

Long glass fiber-reinforced thermoplastics present an excellent lightweight option for vehicle components requiring thinner structures. Although these materials may incur higher upfront costs, automotive suppliers benefit from the cost-effectiveness associated with their lower specific gravity compared to unfilled resins. Notable applications in development or production include brake pedals, seat backs, and airbag housings.

Carbon Fiber-Reinforced Plastics

The quest for lower emissions and improved fuel economy is accelerating the adoption of plastic alternatives to metals like aluminum. Carbon fiber-reinforced plastics stand out for their remarkable properties, being around 40% lighter than traditional materials and offering substantial lightweighting benefits for larger components such as side panels. By utilizing these advanced materials, vehicle weights can potentially be reduced by 50% compared to steel while maintaining safety and structural integrity, with strength that can be up to four times greater.

In recent analysis, the usage of carbon fiber-reinforced plastics in the automotive sector was estimated at 7,000 metric tons, with expectations that this market could expand to nearly 11,000 metric tons in the near future. Leading players in this space include:

• General Motors - The innovative CarbonPro pickup box was introduced as an option for the GMC Sierra, developed in collaboration with Teijin Automotive.
• BMW - The BMW M2 CS features a factory-standard carbon fiber-reinforced plastic roof.
• Porsche - The newly revealed Porsche "Bio-concept Car" predominantly utilizes organic materials, highlighting the use of carbon fibers for weight optimization.

It is evident that the automotive sector is wholeheartedly embracing the possibilities that come with integrating composites in place of traditional metals. For further insights, refer to our extensive guide on designing plastic components for intricate automotive applications below:

Adopting Alternative Materials in Automotive Engineering

Plastics remain crucial in the global market, with more than 400 million tons produced annually for various components and products. However, the rising emphasis on sustainability and obstacles within the plastic supply chain are encouraging automakers and molders to scrutinize how to optimize existing scrap plastic into feasible supply channels.

One of the main challenges has been incorporating their own recycled materials and other post-consumer resins (PCR) with varied viscosities into current injection molding workflows. iMFLUX aims to tackle this issue with pioneering advancements in plastic injection molding technology.

Addressing Resin Variability

Traditional injection molding techniques frequently struggle to process materials with the varying properties found in PCR, including differences in weight, viscosity, and melting temperatures. The absence of a system to manage these variations often results in molded parts that suffer from defects, wastage, and diminished quality. Consequently, manufacturers have continued to rely on a regular supply of virgin resin, despite its cost and negative environmental impact.

Notably, disruptions in global resin supply chains have exacerbated these challenges, leading to reduced material availability for production. Further complicating matters, original equipment manufacturers (OEMs) specify the materials required, meaning suppliers lacking reliable access to such materials risk missing contractual obligations.

iMFLUX resolves these challenges with an innovative low-constant-pressure injection molding system. This technology broadens the range of acceptable materials while allowing the use of alternative resins and PCR with maintained product quality. By utilizing a melt pressure sensor to assess and react to viscosity changes during molding, the system optimizes filling and packing regardless of material content, reducing defects in the end products.

Thus, OEMs and plastic part manufacturers that implement iMFLUX's technology can seamlessly integrate diverse plastics and resins into their processes while achieving heightened quality and efficiency.

Expanded Material Choices = Greater Flexibility

The introduction of a diverse array of materials without compromising quality revolutionizes manufacturing opportunities. Numerous alternative resins can potentially match or exceed the quality of virgin materials, yet improved management during injection molding can unleash their full potential.

Research into these materials is ongoing to better understand how their properties stack up against traditional materials used for injection molding. Just like metals, different plastic resins possess unique characteristics that dictate their suitability for various applications.

• Acrylonitrile Butadiene Styrene (ABS) proves highly effective within automotive bodies due to its energy-absorbing properties.
• Polypropylene (PP) is favored for its resistance to heat, chemicals, and impacts, often found in scuff plates and bumpers.
• Polyvinyl Chloride (PVC) serves as a flame-retardant material with both rigid and flexible types utilized throughout vehicle structures.
• Polycarbonate (PC) is increasingly used in electric vehicles (EVs) due to its lightweight, durable, and adaptable qualities, allowing it to replace heavier metal components without detracting from visual appeal.

These plastics not only deliver necessary durability but also confer additional advantages:

• Weight reduction that enhances overall vehicle performance.
• Lower sourcing and production costs compared to conventional metal components.
• Potential for innovative and distinct designs tailored to specifications from OEMs, regulatory bodies, and end consumers.

Refining Processes Through Testing

Thorough testing of each resin against various parameters will determine optimal combinations for automotive applications. iMFLUX's Auto-Viscosity Adjust (AVA) feature significantly simplifies both testing and subsequent production phases.

The iMFLUX injection molding system offers a means for automotive parts manufacturers to enhance operational efficiency and align with sustainability objectives. In future articles, we will delve into how this technology can also reduce complications associated with sequential valve gates. Reach out to us for additional information.

External Resources

1 https://ourworldindata.org/plastic-pollution#:~:text=The%20world%20now%20produces%20more,our%20natural%20environment%20and%20oceans.

2 https://www.electronicsb2b.com/headlines/electric-vehicle-engineering-plastics-is-a-big-opportunity/

3 https://www.midstatemold.com/the-benefits-of-plastic-parts-in-the-automotive-industry/

4 https://www.imflux.com/the-green-curve-video/

5 https://imflux.com/wp-content/uploads//09/-ii-feature-injection.pdf

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