spe automotive congratulates innovation awards gala winners

8 category winners, the pinnacle 5 winners for the corridor of reputation award and the vehicle engineering team award and lifetime success award winners had been found out on the nov. 10 occasion.

the automobile division of the society of plastics engineers (spe, danbury, conn., u.s.) has announced the winners for its 50th annual automotive innovation awards gala for the car and plastics industries, formerly revealed during the nov. 10, 2021 occasion held at the burton manor in livonia, mich., u.s.

the chassis/hardware class winner became additionally this year’s grand award winner. the grand award winner is chosen from the winners in seven classes through a panel of enterprise-professional blue ribbon judges. a vehicle engineering group award (veta) changed into also introduced. the veta honors work in research, design, engineering and/or manufacturing that has caused the full-size integration of polymeric materials on a remarkable automobile.

similarly, to commemorate “50 years of plastics innovation,” rather than selecting a single hall of fame (hof) winner for 2021, the hof committee selected the pinnacle five main improvements from the preceding 37 winners, ranging from 1983 to 2019. the standards for a hof award is that the nomination has been a game-changing innovation in use for as a minimum 15 years, has been very successful international, includes innovative materials, processes and packages and is still in use. an entire life success award turned into also offered.

this yr, a unique class turned into also added to understand “modern automobile enterprise plastic answers for covid-19 safety.” this honors the effort of the automobile industry to offer private shielding system (ppe) at some point of the early days of covid-19, bringing capacity to the marketplace with car layout and manufacturing strength on the same time most corporations were handling covid-19 shutdowns. winners from this yr’s competition are indexed below in class and submission order:

category winner: additive manufacturing
incorporated tether device
oem make and model: 2021 ford motor co. ford maverick
tier supplier/processor: iac organization/iac institution
cloth dealer/toolmaker: now not to be had/now not applicable
material/procedure: now not available/additive production

in an industry first, customers can pick, down load nftl documents and 3d print their own swappable add-ons (e.g., cupholders, trash containers, and so on.) that in shape in garage slots of their vehicle throughout the entire maverick collection. preliminary designs had been advanced by using ford and its supply teams, however future ones can be counseled through clients. quite a few printer types and advised substances can be used. this presents clients with bendy, customizable garage and use functions or the option to maximize cabin space whilst avoiding huge tooling investment.

class winner: frame outdoors
grille with integrated lit brand
oem make and model: 2021 ford motor co. ford mustang mach e gt
tier supplier/processor: magna exteriors/lexamar div. of magna exteriors
material provider/toolmaker: covestro/inevo group
fabric/manner: laptop/injection compression molding

this hardcoated and painted front grille with lit logo affords a 3d, futuristic impact in a unmarried part. injection/compression molding bureaucracy the huge-format clean computer grille with variable wall thicknesses (ranging from three-five millimeters) in a decrease-tonnage press that helped limit or take away drift strains and strain marks. after molding, the optical-nice component undergoes hardcoat silicone dip to offer excellent weathering and abrasion resistance, the pony emblem is milled out, and primer and paint are selectively implemented to the b facet of the component — said to be the primary use of paint-over-hardcoat for an auto outside trim utility.

category winner: frame indoors
0.33 row seatback
oem make and model: 2021 toyota motor corp. toyota sienna
tier dealer/processor: toyota boshoku corp./flex-n-gate corp.
cloth dealer/toolmaker: basf corp./concours technology inc.
material/manner: ultramid b3zg7 cr pa 6/injection molding

a 16-piece steel meeting become replaced with a unmarried, shoot and ship plastic assembly for this 1/3-row seatback that decreased mass 30%, price 15%, represented a two-time development in crash overall performance and takes 63% much less effort for occupants to raise the seat to its upright role, disposing of the need for a seat motor. that is enterprise’s first absolutely-plastic freestanding seatback imparting tremendous electricity absorption with out need for steel guide brackets. a brand new 35% brief-glass, effect-changed pa6 resin became advanced for this sequentially injected application.

“that is a first-rate reputation for us. this seat is 30% lighter in comparison to the preceding model and is price competitive whilst nonetheless exceeding all performance standards,” says todd muck from the body design seats group at the toyota r&d middle in saline, michigan. “this would no longer have been possible without the toyota seat crew and the assist of basf and flex-n-gate.”

grand award and category winner: chassis/hardware
multi-material rear leaf spring
oem make and version: 2021 ford motor co. ford f150
tier dealer/processor: rassini suspensiones/rassini suspensiones, sgl carbon
material provider/toolmaker: hexion inc., sgl carbon/now not to be had
cloth/procedure: epikote resin trac 06150, epikure curing agent trac 06150, heloxy additive trac 06805/high stress transfer molding (hp-rtm)
this hybrid rear leaf spring combines a high-electricity metallic primary percent plus an hp-rtm fiberglass-reinforced epoxy composite helper that reduces mass 30% even as presenting the identical stiffness and durability as a conventional metal leaf spring device. extra advantages include extended payload capability, lower part count number, reduced interleaf friction, smoother engagement, lower noise and decrease carbon footprint.

class winner: environmental
wiring harness clip
oem make and version: 2021 ford motor co. ford bronco recreation
tier provider/processor: lear/hellermanntyton north the usa
material dealer/toolmaker: dsm/hellermanntyton north the us
cloth/procedure: akulon repurposed pa6 pa6/soften compounding, injection molding

these 15% gr rpa6 wire-harness clips are injection molded from one hundred% pcr ocean plastics. ghost equipment (fishing nets) are gathered by using fishermen inside the indian ocean and arabian sea, supplying jobs, extra sustainable livelihoods and more healthy marine lifestyles. the fabric presents similar performance to petroleum-primarily based top resin at 10% fee savings, lower power, progressed deliver-chain stability and lca blessings. no tooling adjustments and minimum process changes had been wished for this drop-in change.

category winner: substances
composite roof receivers
oem make and version: 2021 stellantis jeep wrangler and jeep gladiator
tier dealer/processor: stellantis/no longer available
material dealer/toolmaker: mitsubishi chemical superior substances /maple mold generation
cloth/technique: kyronmax s-4330 ppa w /30% uscf/injection molding
six brackets for removeable hardtop and tender top roofs have been transformed from investment forged steel to 30% ultrashort carbon fiber (uscf)-bolstered ppa, providing similar element electricity while lowering fees 38% and mass 79%. powder coating became removed and scratch and mar advanced while providing a weatherable, mic, elegance a finish that allowed for mid-software substitute and backwards carrier compatibility. the uscf composite molds like neat polymers but outperforms lft substances, is completely recyclable, and has a lower carbon footprint than metallic/alloy parts. direct-drop valve gates and t-nut fasteners additionally had been key enablers.

class winner: method/assembly/permitting technology
thick lightbar improvement
oem make and version: 2021 popular automobiles co. cadillac escalade
tier supplier/processor: valeo lights systems/valeo lighting structures
fabric supplier/toolmaker: covestro llc/windsor mold institution
fabric/process: makrolon led computer/multi-cavity, multi-shot injection molding

this challenging 780-millimeter-long and 18-millimeter-thick obvious-crimson mild blade for rear taillamps features offers a completely unique look and homogeneous lit look. keys to making the patented software work were advanced simulation tools for layout and useful optimization and warpage manipulate; complicated runner, parting line, shutoff valves and multi-shot injection system manipulate; plus a custom-formulated optical-grade of laptop that helped manage best, cost and molding capability and met all felony rear-lighting necessities. despite technical demanding situations, application timing became decreased by means of three months and $250,000 in prototype tooling became prevented thru virtual prototyping.

class winner: industry answers for covid-19
powered air purifying respirator
oem make and version: 2020 ford motor co. constrained use papr
tier dealer/processor: ford motor co./denso corp.
material provider/toolmaker: asahi kasei the united states inc., celanese/ 3dimensional offerings, protolabs
cloth/method: pptd40, pom asahi p-40tc-1102 nt101, celanese m90 cf2001 polypro, pom/injection molding

the group produced what’s stated to be the primary all-plastic papr, converting previously steel components to plastic to lessen mass and fees and enhance person comfort for this non-public defensive device (ppe_ utilized by medical workers being concerned for covid-19 sufferers. the lighter, greater green design advanced battery lifestyles, enabling people to complete a 12-hour shift without having to recharge the battery. niosh certification turned into accomplished in only 3 days on the first try. manufacturing turned into increased to eight,500 devices/week from the 650/week the previous supplier done. all income from sales have been donated to covid-19 relief funds and 4 patents are pending at the unit.

category finalists: enterprise solutions for covid-19
ventilator principal chassis manufacturing
oem make and model: 2020 popular automobiles co./ventec lifestyles structures v+seasoned emergency ventilator
tier dealer/processor: hitech mildew & engineering inc./hitech mould & engineering inc.
fabric supplier/toolmaker: sabic/hitech mold & engineering inc.
cloth/system: lexan 500r 10% gf computer/injection molding and threaded insert meeting
in much less than 18 days, the crew sourced substances, built tooling, delivered dimensional excellent into spec, automatic installation of 48 brass insert nuts (confirmed by way of imaginative and prescient systems), transformed a manufacturing facility, trained a group of workers and scaled up manufacturing of tight-tolerance ventilator chassis components from hundreds/12 months to heaps/week, sooner or later delivering 30,000 over 154 days. whereas the previous dealer had struggled to meet accuracy, ftq become raised to 98.7 at faster production instances.

emergency ventilator
oem make and version: 2020 widespread automobiles co./ventec life systems v+seasoned emergency ventilator
tier provider/processor: cascadia custom molding/west michigan molding inc.
material supplier/toolmaker: avient corp./proper organization international inc.
fabric/manner: versollan om1262nx-1 tpe/injection molding
the team evolved a unique tpe — supplying modified drift, high adhesion to the pc/abs substrate and superb chemical resistance — and shipped it within 24 hours. excessive-cavitation tooling turned into unexpectedly produced to make sure sufficient supply. a solid deliver chain become hooked up that met call for all through 2020.

warpage correction in ventilator o2 bracket
oem make and model: 2020 general vehicles co./ventec lifestyles systems v+seasoned emergency ventilator
tier supplier/processor: pti engineered plastics/pti engineered plastics
material supplier/toolmaker: victrex p.c/pti engineered plastics
material/technique: vitrex 450fc30 peek/injection molding
in less than one week, the peek resin became completely characterised for cae material cards and tooling for a key ventilator thing became redesigned the use of mold morphing/windage strategies to cope with warpage issues that had previously required submit-mold fixturing and machining. new tooling became produced and first elements had been shot nine days later. this allowed the crew to keep extraordinarily tight tolerances with out post-mildew countermeasures. this enabled manufacturing to be scaled from thousands/yr to thousands/week to meet excessive demand. costs have been decreased 30-forty% by way of doing away with publish-mildew machining.

ventilator diaphragm
oem make and model: 2020 ventec lifestyles systems v+seasoned emergency ventilator
tier supplier/processor: ventec lifestyles structures/lumenflow corp.
cloth supplier/toolmaker: wacker chemical corp./2k tool
fabric/process: elastosil lr 30003/50 silicone rubber/liquid silicone injection molding
the team used its car skillset to retrofit processing gadget to exchange from optical-grade silicone to standard liquid silicone rubber, resolve a void difficulty, construct new tooling in just 19 days, and ramp up manufacturing of a essential ventilator diaphragm from 1,000/yr to 4,000/week.

bendy air breathing tube for powered air purifying respirator (papr)
oem make and model: 2021 ford motor co. powered air purifying respirator
tier supplier/processor: ti fluids systems/flexaust
fabric supplier/toolmaker: celanese, at polymers, techmerpm, ineos styrolution institution gmbh, dupont/now not available
fabric/system: eva, ldpe, pe, abs, pa6/6/thermoforming and injection molding
to meet niosh certification necessities, the group used automotive equipment to deliver on all task objectives in much less than 30 days. a new breathing tube layout became developed where one length suits our bodies starting from 5th percentile lady to ninety fifth percentile male in plenty of postures. the layout features short connects to make certain a robust connection and gives 25% greater airflow but consumes 24% less modern-day for prolonged battery life. it is also lighter and 8 db quieter. the crew delivered 42,000 respiratory tubes at some stage in this system.

ppe production through #tyvektogether and assignment airbridge
oem make and model: no longer relevant
tier provider/processor: now not relevant/now not applicable
material dealer/toolmaker: dupont/no longer applicable
material/technique: tyvek/now not relevant
two special programs — operation airbridge and #tyvektogether —dramatically extended manufacturing potential for sanatorium gowns and coveralls for healthcare people and primary responders. additionally, a new cloth become formulated in only 3 weeks to optimize use and growth downstream production. idle capability and sources at 15 u.s.-primarily based companions have been used. in overall, the team produced and shipped 17.6-million garments to top off the country wide stockpile.

multi-use isolation robe
oem make and version: 2020 ford motor co. isolation robe
tier supplier/processor: joyson, windsor/not applicable
cloth provider/toolmaker: highland industries, aunde/not applicable
material/method: nylon 6,6, polyester/weaving, coating, stitching
responding to the shortage of ppe early in the pandemic, the team repurposed airbag and seat trim materials and used idle cut and sew centers to provide 50 times the washer-friendly isolation robes for frontline employees. unique fabrics had been developed and accepted in less than two weeks (pa6/6 with silicone coating and pet with paraffin/c6 fluorocarbon coating) and robe designs have been changed to save you sleeves from driving up whilst employees were gloved. a complete of 1.32-million robes had been shipped thus far. efforts have been made to lessen robe cost to fitness-care carriers.

apollo ppe face guard
oem make and model: 2020 ford motor co. ppe face defend
tier dealer/processor: troy layout mfg/placon
fabric dealer/toolmaker: ex-tech/placon
material/method: pet apet & rpet pe/die cutting and rotary reducing
that is reported to be the first time this kind of ppe equipment has been produced at extremely excessive volumes. within days’ time, the group evolved its first clear face shields and within 13 days, 1.1 million devices have been produced and brought. to address supply constraints and ability failure modes, fabric turned into modified from rpet to apet and pushpin attachments replaced stapling. supply streams and production groups have been capacitized to greater than five million portions/week. in general, over 21 million units had been shipped to guard frontline workers.

acteev technology
oem make and model: no longer to be had
tier provider/processor: now not to be had/no longer to be had
cloth supplier/toolmaker: now not to be had/now not to be had
material/process: not available/spunbond and meltblown nonwoven media; non-stop filaments, monofilaments and staple fibers; molded applications
a new low-odor material brought in nov. 2019 changed into repurposed to produce washer-friendly and reusable nonwoven face masks for the pandemic. key to the cloth’s efficacy is the truth that zinc ions are embedded inside the polymer matrix during polymerization, so the antibacterial treatment doesn’t wash or put on off and remains lively for the life of the product. the technology also can be used for knits, woven fabrics and engineering plastics and is covered via greater than 100 patents up to now.

class winners for the top five hall of repute awards from 1983-2019:
hdpe (high-density polyethelene) gas tank: awarded to volkswagon ag in 2000.
front & rear tpo (thermoplastic polyolefin) bumper fascias: offered to preferred vehicles co. in 2010.
pvb (polyvinyl butyral) windshield interlayer: provided to ford motor co. in 1988.
pa (nylon) thermoplastic consumption manifold: provided to porsche ag in 2005.
laptop (polycarbonate) headlamp assembly: offered to ford motor co. in 2007.

category winner for automobile engineering group award (veta): ford motor co. 2021 ford f-150
the team at ford motor co. (dearborn mich., u.s.) and its suppliers that developed the 2021 version 12 months ford f-one hundred fifty pickup has been named the veta winner.

the veta award become created by way of spe in 2004 to apprehend the technical achievements of whole teams — made out of car designers, and engineers, tier integrators, materials suppliers, toolmakers and others — whose paintings in research, design, engineering and/or manufacturing has caused sizable integration of polymeric materials on notable motors. for forty four years, f-series has been the bestselling pickup in the u.s. and the 2021 version features numerous plastics and composites improvements, lots of which had been nominated in different categories of this yr’s competition, together with:

frame exterior nomination
cowl vent grille
body interior nominations
armrest insert
max recline seat
first row middle seat cell laptop
higher glovebox with far flung launch
work surface foldout armrest
chassis/hardware nominations
multimaterial rear leaf spring
folding shifter
substances nomination
coolant float control baffle

category winner: lifetime achievement award:
nippani r. rao (1939-2021), a pillar inside the automobile enterprise and long-time board of director for the spe automotive and spe composites divisions and spe detroit section, has been named spe’s lifetime fulfillment award winner for 2021 posthumously. nippani rao contributed many years of thoughtful and accountable management to spe resulting in conferences, occasions and programs progressed from his management. in the course of his enterprise tenure, nippani served in may additionally main spe roles:

spe car department – board member
spe composites department – board member
spe detroit section – board member
spe automobile department lifetime fulfillment award – chairperson
spe automobile department hall of fame awards – chairperson
blue ribbon committee for the spe car innovation awards – decide
spe detroit section – awards committee chair
spe acce part competition – decide
spe detroit segment – tpo convention founder
energetic in the tpo conference because its inception in 1999
energetic inside the acce conference seeing that its inception in 2001
spe detroit segment annual golf time out – resurrected the event
his paintings enjoy includes:

president, rao pals: 2009-2021
generation manager, asahi kasei llc: 2008-2010
substances engineering manager, chrysler llc: 1986-2008
nippani’s engineering responsibility blanketed the award-winning stay clear of viper body innovations with rtm. he has severa cloth patents. nippani greatly valued spe and made positive chrysler stayed worried in the society.

formal education consists of:

xavier university, ms and mba, chemical engineering and advertising and marketing
college of cincinnati, grasp’s diploma, chemical engineering
awards:

spe detroit segment – commemorated service member
the spe automotive div. was proud to honor nippani r. rao with the 2021 lifetime fulfillment award posthumously and a tribute at this yr’s spe car div. innovation awards gala.

 

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