Page 40 - Plastics News January 2022

FEATURE

Process Assembly/Enabling Tech- patented application work were advanced personal protective equipment is used by
nologies: Thick Lightbar Develop- simulation tools for design and functional medical workers caring for COVID-19
ment optimization and warpage control; patients. Tier and processor contributors
This challenging 780 mm long × 18 complex runner, parting line, shutoff were Ford and Denso Corp. Material
mm thick, transparent-red light blade valves, and multi-shot injection process suppliers were Asahi Kasei America
for rear taillamps, featured on the control. Also key is a custom-formulated and Celanese, and toolmakers were
2021 GM Cadillac Escalade, offers a optical-grade of Covestro’s Makrolon 3Dimensional Services and Protolabs.
LED PC that helped manage quality, Asahi Kasei’s TD40 40% talc-reinforced
cost, and molding capacity and met all PP was used for the injection molded
legal rear-lighting requirements. Despite breathing-tube adapter, filter cover,
technical challenges, program timing was electronic cover and blower housing.
reduced by three months and $250,000 The battery cover was transitioned from
in prototype tooling was avoided through PP-TD40 to Celanese’s Hostaform/
virtual prototyping. Celcon POM (polyacetal). The lighter,
more efficient design improved battery
Industry Solutions for COVID-19: life, enabling workers to complete a 12-
Powered Air-Purifying Respirator hr shift without needing to recharge the
Ford Motor’s 2020 NIOSH-certified, battery. Production was increased to 8500
unique appearance and homogeneous Limited Use APR (Powered Air-Purifying units/week from the 650/week achieved
lit appearance. Tier supplier/processor Respirator), the first all-plastic product by the previous supplier. All profits from
is Valeo Lighting Systems and material of its type, converted previously metal sales were donated to COVID-19 relief
supplier/toolmaker are Covestro and components to plastic to reduce weight funds. Four patents are pending on the
Windsor Mold Group. Key to making the and cost and improve user comfort. This unit.

coo@aipma.net

40 PLASTICS NEWS JANUARY 2022