Innovation Honored

The Society of Plastic Engineers is a decidedly international organization, with 20,000 plastics engineers in 70 countries.

This year's 35th Annual Automotive Innovation Awards reflect that global presence, as European, Asian and U.S.-based auto makers share in the top honors. Judges at this year's competition include members of the media (including Ward's) and academia, plastics analysts and retired auto industry executives. Here are the 2005 winners:

Safety: A European-focused technology snagged top honors. The '04 Volkswagen Golf's pedestrian-protection system features a textile reinforced glass-mat-thermoplastic (GMT) composite beam that fulfills the European Union's new pedestrian-safety standards. The beam offers a 30% weight savings and 50% material cost savings vs. steel. AKSYS GmbH is the supplier.

Process/Assembly/Enabling Technologies: The first bonded hybrid metal-plastic front-end carrier, on the '05 VW Polo, features an injection-molded thermoplastic-composite component reinforced with metal. By bonding the parts together, stress concentrations are reduced, and the load is spread over the structure, enabling high stiffness. Portugal-based Grupo Simoldes is the system supplier.

Powertrain: The water-jacket spacer in the Lexus GS 300 is molded in polyphthalamide thermoplastic. It is the first water-jacket spacer designed for open-deck engines, which place a high degree of thermal stress between the cylinder head and block. The spacer improves fuel economy by using coolant to transfer heat away from the cylinder bore liner. Aisan Industry Corp. is the supplier.

Performance and Customization: The mid-box door assembly on the Chevrolet Colorado and GMC Canyon commercial pickups consists of a thick-sheet thermoformed outer skin with paint film bonded to the inner steel structure, creating the largest and flattest application of a Class A body panel. Decoma International is the system supplier.

Materials: The molded-in-color reactor Thermoplastic Olefin (TPO) airbag cover in the '06 Buick Lucerne provides 20% weight savings and cost savings of 45%-65% over conventional painted covers. Autoliv Inc. is the system supplier.

Environmental: A spare-wheel cover with abaca-fiber reinforcement on the '05 Mercedes A-Class is the first large-scale use of natural fiber reinforcement for an exterior. Abaca is a plant native to the Philippines. Its leaf sheath fibers are harvested to make ropes, clothing and paper-based materials. Processing abaca requires 60% less energy than producing glass fibers. Reiter Automotive is the supplier.

Chassis/Hardware: The all-plastic window regulator on the '06 PT Cruiser replaces a steel component and reduces parts from 21 to 13. The new component needs two attachment points on the vehicle, instead of five. The glass-filled nylon part is recyclable. Dura Automotive is the supplier.

Body Interior: The '04 Pontiac Grand Prix's climate-control vents, from Delphi Corp., exchange the traditional rudder for a composite “film” that meters airflow within a confined space — offering 13 thermal settings. The system reduces rattles and vibrations as well as air-rush noise.

Body Exterior: The industry's first composite in-bed trunk on the '06 Honda Ridgeline permits a lockable storage area in the cargo bed, high carrying capacity, better impact strength and corrosion resistance. The supplier is Meridian Automotive Systems.