Mustang Muscle

The Body Exterior category champion was the body-color blow-molded running board on General Motors Corp.'s '05 fullsize SUVs. It's the first part to use body-colored matched twin-sheet thermoformed paint film technology. The large blow-molded structural exterior part — greater than 90.5 ins. (230 cm) in length — is 30% lighter and 30% more durable than the competing technology. “We saved GM $60 million a year,” says Tim Chapman, engineering director for supplier ABC Group.

The Body Interior category title was shared by two entries. The composite steel hybrid instrument panel carrier, which was used for 12 vehicles, including the Volvo S40/V50, Mazda3 and Ford Focus C-Max cars, was one winner. The compression-molded 1-piece part integrates the ventilation and defrosting systems, and nearly 12 other features. It's compatible with left-hand and right-hand configurations. Weight was reduced by about 4.5 lbs. (2 kg) vs. steel systems.

The other winner in the category was the '05 Ford Mustang's door trim with an integrated acoustic chamber and subwoofer. The injection-molded part, developed by Visteon Corp. and Ferro Corp., includes tunable features within the impact zone of the integral chamber to meet side impact performance requirements without the use of a standard hip bolster. The door trim provides weight savings of more than 18 lbs. (8.2 kg) vs. the previous Mustang, while reducing cost by 30%, as well as eliminating about 20 part numbers.

The Chassis/Hardware category title was snagged by Chrysler Group, DuPont Automotive and Mayco Plastics for the structural mirror bracket on the '04 Dodge Durango and Dakota. It's the first structural use of polymer to reinforce sheet metal body panels in the body-in-white stage. The mirror bracket replaces a welded-steel part and provides 86% weight reduction.

The Environmental category crown was awarded to the fan shroud module on GM's fullsize pickups and SUVs. The project used recycled post-consumer mineral/glass nylon to make the fans and shrouds. The electrically driven — a first for light trucks — fan and shroud replace conventional engine-driven versions.That increases fuel efficiency by 2 mpg (118 L/100 km).

The '05 Mustang also won the materials category. The award was for the 2-shot load-bearing touch-off molding. It's the first time an all-plastic component has been used for that molding application on a convertible. The multi-shot injection-molded part reduces cost by 40% and weight by 40%.

Top honors for Performance and Customization went to Cequent Towing, Composite Technologies, Brinkman Tool and Die and Alliance Gas Systems for the gas-assist towing package. It is the first gas-injection thermoplastic compression-molded aftermarket part. The technology enables the production of structural long-glass polyprolene components with thinner cross-sections, eliminating part distortion, while maintaining aesthetic appearance, reducing part weight about 0.5 lbs. (0.2 kg).

The Powertrain category winner was from a commercial vehicle, the '03 DaimlerChrysler Actros BR500's oil pan module made by KTSN, BASF Corp. and Hause Presswerkzeugbau. It's the first thermoplastic oil-pan module. An injection-molded part, the oil-pan module is 1 dB quieter than its aluminum predecessor and holds 30% more oil.

The Process/Assembly/Enabling Technologies category was another '05 Mustang part: the simultaneous shot injection-molded instrument panel by Visteon Corp., Advanced Composites and Lamko Tool & Mold Inc. The Class A molded-in-color polypropylene instrument panel lower gives a 2-tone appearance without painting. That reduced volatile organic compound plant emissions by an estimated 3.6 tons (3.3 t) annually.