Innovation

PATENTED WHEEL LINER HYBRID

US Patent # 9,039,074

Hybrid Structure Advantage:

  • Rigidity & shape complexity of plastic skeleton
  • NVH & Lightweight of non-woven material

Optimized material technological yield

Design Innovation:

  • Interface between structures
  • High reliability output potential

Manufacturing Process Innovation:

  • Automation of production process
  • Confirmed consistent performance and quality levels

Extension usage opportunities:

  • Hybrid structures for Aeroshields, Trunk, Under the Hood applications
  • Process adjustment (patent extension in progress): replace overmolding with 1 step (dual material) forming
  • Functionality extension for interior vehicle modules

SPLIT & MODULAR WHEEL LINER CONCEPT

Challenges of traditional design
  • Deep part with high technological scrap tool build process
  • Low reliability & high maintenance cost manufacturing process
  • Expensive manufacturing infrastructure
Advantages of modular concept:
  • Increased part design freedom
  • Lower tool cost
  • Modular parts with shared tools & components
  • High reliability & low maintenance cost manufacturing process
  • Reduced machine size

ECO-FRIENDLY STRIKER ASSEMBLY

  • Simplified design / simplified manufacturing process
  • Virtual and physical validation for a safety-related component
  • Modular concept: multiple design options with shared components and tools
  • In-house equipment build
  • Reduced energy consumption and water-based metal insert rust proofing
  • High efficiency manufacturing process

/

ENHANCED PERFORMANCE FRONT ABSORBER

Particle expansion (EPP) part:

  • Extreme lightweight (100g/l density)
  • Complex geometry with thin & variable wall thickness
  • FEA validated functionality

Dual functionality in one component:

  • Impact counter-measure for pedestrian protection
  • Air-flow management

HYBRID INJECTION MOLDING TOOLS

Multiple material concepts fitting specific program requirements:

  • Steel inserts for critical areas:
    • Material landing (runner system) areas
    • Parting line closing
    • Guidance / ejection components
  • Aluminum blocks for core/ cavity
  • High thermal transfer inserts for temperature control
  • Anti-friction inserts for slides / lifters

COBOT (COLLABORATIVE ROBOT) BASED ASSEMBLY

Highly flexible setup & functionality
Possibility to automate assembly segments while allowing operator joint work
In-house expertise:

  • Program & setup cobot
  • Completely develop work cell
TOP