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a comparable solid part. Extensive CAE work predicting warpage of the foamed part provided valuable insights, allowing for modi- fication of tooling in advance. Going forward, BMW and partners see this as an industry benchmark for IP carriers. CHASSIS/HARDWARE: POWERTRAIN BRACKET Appearing on the 2017 GM Cadillac XT5 crossover SUV, this engine clevis mounting bracket is reportedly the first com- posite mount designed for a six-cylinder engine. Injection molded by Hutchinson, the part is made from Ultramid A3WG10 CR BK00564, a 50% glass-reinforced nylon 66 from BASF Engineering Plastics, Budd Lake, N.J. (basf. com). It replaces the stamped, welded, and die-cast metals used previously, resulting in a 45% weight reduction, as well as improved NVH (noise, vibration and harshness) due to the damping char- acteristics of the nylon. Corrosion resistance is also improved, and the part can be recycled at end of life. Seven clevis brackets were developed for different powertrain combinations and have experienced no warranty claims after 1.5 years of production. MATERIALS: LOW-FRICTION NYLON FOR CHAIN TENSIONER Stanyl HGR2, a nylon 46 modified with PTFE from DSM Engineered Plastics, Troy, Mich. (dsm.com), is used for chain- tensioner arms on the 2017 Ford F-150 pickup and Ford Mustang sports car. The material was a drop-in replacement for nylon 66 to provide enhanced wear and friction performance. The resul- tant fuel-economy savings (0.4%) from rotational torque reduc- tion in the cam shaft was equivalent to a 40-lb weight reduction, at 10% of the cost. This innovation is highly transferable to provide affordable fuel-economy improvement, and will be utilized on more Ford vehicles beginning in 2018. POWERTRAIN: TURBOCHARGER OUTLET T-JOINT Featured on the 2018 Hyundai Genesis G80 and Kia Stinger sedans, this turbocharger outlet T-joint is injection molded from Zytel XT, a new 35%-glass, heat-stabilized nylon 66 which was developed for long-term retention of properties at up to 220 C/428 F by DuPont (now, DowDupont; dow-dupont.com). Molded by Hwaseung R&A; Ltd., this part achieves a 42% weight savings and a 35% cost reduction, along with improved airflow, reducing the pres- sure drop to increase fuel economy and improve NVH performance compared with the previous die-cast aluminum part. Airflow noise is also reduced and long-term durability increased via the rib pattern design. Special three-gate tooling was designed to minimize stress in the weld-line area for strength and durability and for processing optimization. PROCESS/ASSEMBLY/ENABLING TECHNOLOGIES: TWO-SHOT INTERIOR BEZEL The unique 3D decorative effect on this interior bezel, which appears in the 2018 Ford Fiesta subcompact, is achieved with QUESTIONS ABOUT AUTOMOTIVE PLASTICS? Visit the Automotive Zone. Thermoplastics gain serious ground in new automotive applications. Heat-stabilized, glass-reinforced nylon 66 turbocharger outlet T-joint achieves a 42% weight savings and 35% cost reduction. The 2018 Ford Fiesta subcompact features a unique two-shot interior decorative bezel, said to be a first for a part of this size and geometry. 16 JANUARY 2018 Plastics Technology PTonline.com S P E A U T O M O T I V E Close -Up On Technolog y