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attaching system for consistent fit between the grille and head- lamps, which eliminates the need for FEM (finite-element method) assembly, dunnage, and shipping. The material used by injection molder Magna Plastcoat is Celstran 40% long-glass PP from Celanese Engineered Materials (celanese.com), Irving, Texas. The use of LFRT (long-fiber-reinforced thermoplastic) to develop a structure with PP offset an estimated 3 lb of weight over alternative nylon-overmolded metal hybrid designs. An equivalent all-steel struc- ture would weigh 18 lb more than the LFRT design, which delivers the required durability. In addition to reducing variable and piece costs by an estimated $5 with an all-thermoplastic solution, the enhanced design saved $16 in assembly cost per vehicle and eliminated around $45 auxiliary costs. Improved parts consolidation also eliminated four separate fasteners and associated labor. Ford will be using similar parts on all of its trucks. BODY INTERIOR: LGF-PP IP CARRIER The instrument-panel (IP) carrier in the 2017 BMW Mini Countryman utilizes Stamax 60YK270E high-flow, long-glass-fiber (LGF) PP copolymer from SABIC, Houston (sabic.com). International Automotive Components (IAC) injection molded the part via chemical foaming with a core-back process. Use of 60% long glass achieved a 1.9-mm wall thickness, increasing stiffness at lower weight. Use of foaming resulted in a 15% weight saving vs. Spanning nine categories, the winners of the SPE Automotive Division's 2018 Blue Ribbon Automotive Innovative Awards (which this editor helped judge) represent a number of "firsts" in metal replacement and in replacing earlier plastics solutions with better options. In this 47 th annual competition—the oldest and largest such event in the automotive and plastics industries, all but one category entailed the use of thermoplastics. BODY EXTERIOR: PP-LFT STRUCTURAL GRILLE This PP long-fiber-thermoplastic (LFT) structural active grille shutter (AGS) with integrated loose-layer construction, was also the Grand Award Winner. It appears on the 2018 Ford Expedition luxury SUV and is said to be the largest two-shot AGS in produc- tion today. It was designed with an integrated locating and By Lilli Sherman Senior Editor Winners of 2017 SPE Automotive Awards Wow with Many 'Firsts' Innovative, transferable, and intelligent use of thermoplastics capture eight of nine categories. A PP LFT structural active grille shutter won the Grand Award. The LGF-PP instrument-panel carrier was chemically foamed with a core- back process, reducing weight by 15%. This engine clevis bracket is said to be the first thermoplastic composite mount for a six-cylinder engine Enhanced with PTFE, this nylon 46 replace nylon 66 in the chain-tensioner arms of the 2017 Ford F-150. 14 JANUARY 2018 Plastics Technology PTonline.com S P E A U T O M O T I V E Close -Up On Technolog y