Page 33 - Plastics News April 2018

FeAtures

Advanced Plastics Make Tomorrow’s Vehicles More Efficient,

Affordable, and Attractive

A look at how selecting the right plastic can reduce material and manufacturing costs while improving
durability.

hen engineering-grade resins were introduced in the Metal-To-Plastic Conversion a Plus for the Au-
W1950s, some auto manufacturers were unfamiliar tomotive Industry
with the benefits of metal-to-plastic conversion, i.e. how
to design plastics into products, and how to manufacture With appropriate design, plastic parts can perform as well
with plastics. Today this practice, also known as as metal in many automotive applications. For example,
“lightweighting,” is becoming increasingly popular with plastic parts can achieve the same tight tolerances,
automakers as they race to comply with a federal mandate but require fewer secondary manufacturing operations.
calling for automobiles to average 54.5 miles per gallon Including additives such as glass-fiber and carbon-fiber can
by 2025. help plastics deliver comparable tensile strength in certain
components like brackets and exterior panels.Plastics also
Converting existing metal products or parts to plastic exceed metal in several key areas. This includes highly
increases fuel efficiency because metal is far heavier repeatable production with less scrap, up to six times
than plastic and, with proper design, engineered plastic longer tool life, enhanced regulatory compliance, and
parts can be just as strong as metal and cost less. Plastics’ greater design flexibility.Until recently, most engineers
chemical resistance and heat resistance, combined with who worked primarily with metal parts were not familiar
their lighter weight, make them especially useful for with the history or success of reinforced plastics. Here are
fuel systems, fluid handling systems and other under-the- a few of the reasons why this metal-centric perspective
hood, high-temperature applications. With developments is rapidly fading from the scene.
in materials and technologies, plastics like polyether
ether ketone (PEEK) are being used for vehicle body
components and an increasing number of working parts
(Figure 1). Some common applications include piston
rings in automatic transmissions and wear plates in gear
systems.
Other engineered plastics have dampening qualities that
absorb vibration better than metal, and can be formulated
to be thermally and electrically conductive. This makes
them ideal for use in electromagnetic interference (EMI),
radio frequency interference (RFI) shields, and acceptable
for certain types of heat sinks.

Lower Cost

Competition has become tough in the global automotive
marketplace and operations are squeezed to be lean.

Let’s say you are using a metal part. If a plastic part is
just as good as the metal part, if not better, why change
to plastic if there’s no compelling performance advantage?
The answer is because in addition to meeting specs for
durability, strength and style, injection- or insert-molded

33 April 2018 Plastics News