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thrust bearings. Thrust bearings of PAI and PEEK now replacing axial needle bearings can save 2.5 mm/0.098 in. per bearing. This space savings enables designers to downsize aluminum housings and achieve significant weight savings. Torlon PAI is known for maintaining strength, stiffness, and toughness at high tempera- ture. Its claim to fame is wear resistance in both lubricated and dry environments. Some grades specially formulated for wear resistance include ones with PTFE and graphite, carbon fiber, and carbon fiber plus PTFE. KetaSpire PEEK reportedly offers better fatigue and wear resis- tance, higher impact strength, and higher ductility than other PEEK products. Wear-resistant grades used in powertrain compo- nents include carbon fiber or graphite with PTFE. Celanese's CoolPoly thermally conductive plastics, which come in electrically conductive and insulative grades, have taken hold in automotive heat sinks by matching thermal properties of aluminum while offering weight and cost savings. These plastics enable 40-55% mass savings due to reduced density and design optimization. A commercial use is in the Ford Mondeo lighting module, where replacing die cast aluminum saved 54% in weight. CoolPoly is also being evaluated for metal replacement in power electronics and lighting. For underhood parts such as radiator air fans, the leading producer of styrene-maleic anhydride (SMA) copolymers, The Netherlands' Polyscope (U.S. office in Novi, Mich.; polyscope.eu), is developing highly glass-filled SMA/nylon blends to address water-absorption issues of nylons and replace over- engineered nylons, according to CEO Patrick Muezers. Houston-based SABIC (sabic.com) sees PP making its way into underhood applications. Scott Fallon, global leader of SABIC's automotive business, points to the 2016 SPE Automotive Innovation Award powertrain winner: the air-intake manifold in VW's 2015 EA21 1.6L engines, said to be the first such part launched in China using 35% glass-reinforced PP to replace nylon 66. The part provides a 25-30% cost reduction and 15-20% weight reduction while retaining properties and improving weld strength. SABIC's G3135X PP in this part utilizes finer glass fibers and special sizing. AESTHETICS, AERODYNAMICS & STRUCTURAL PROPERTIES Automotive interiors str one key focus for A. Schulman, Fairlawn, Ohio (aschulman.com), says Frank Roederer, senior v.p. & general manager for North America. He and his European counterpart Heinrick Lingnau, point to the growth of touchscreen tech- nologies that demand special- ized plastics and the demand for plastic parts with the look and feel of natural materials. The firm's high-flow, low-emissions Schulablend M/MK ABS/ nylon and M/MW ASA/nylon and other alloys offer the potential to eliminate painting and achieve a consistent low-gloss/matte finish. Available in UV-stabilized custom colors and low gloss, they are found in trim such as loudspeaker grilles, pillar covers, instrument panels (masks, end caps, HVAC bezels), trunk and window frames, seat side shields, and AV system bezels. Roederer also highlights softer flexible materials like Polyvin PVC and Invision TPEs for decorative trim like door and console armrests, shifter knobs, bin liners, and cup holders, which need a dry-to-the- touch and non-tacky feel. Polyfort filled, unfilled, and impact-modi- fied PP in UV-stabilized custom colors also get play in pillar covers, door and instrument-panel components, and rear-quarter trim panels. Lingnau also notes the higher-quality appearance trend in exte- riors, where Schulman's fully compounded materials are replacing painted parts in metallic colors. The company provides silver metallic compounds by using special pigments and mineral fillers to achieve metallic optics without weld lines and injection marks. This earned the 2016 Grand Innovation Award of SPE Europe for the Mercedes Benz GLA skid plate for front and rear bumpers, produced with Polyfort FIPP 10 T K2369, a silver-metallic, impact-modified PP compound using an innovative filler system. Meanwhile, car makers are striving to make premium inte- riors affordable, says Trinseo's Mazur. They want surfaces to have a high-quality look and feel, to be durable and less expensive to manufacture in order to pass savings on to customers. This is why the OEMs have stringent requirements for plastics with aesthetics and haptics and best-in-class scratch resistance, along with good processability and cost-effectiveness. Trinseo focuses on interior applications for its Velvex family of factory-colored TPOs with glass reinforcement. "With these products, we bridge the gap between technical and aesthetic performance, and we're doing so at an affordable cost," says Mazur. These materials boast improved soft touch, outstanding scratch resistance, and low gloss while meeting key requirements 2017 Renault Espace lift gate is made of Trinseo's 60% long-glass PP. Trends toward smaller, more fuel- efficient vehicles and electrification have placed a premium on more heat-resistant materials. 46 JUNE 2017 Plastics Technology PTonline.com M ATERIAL S