ENGINEERING PLASTICS
APPLICATIONS
INTRODUCTION
Advancements made in engineering materials technology have
resulted in a situation where metallic materials are no longer the
only choice available for various applications. Over the last 30
years, plastics have been rapidly developed to the point where
they have already started replacing many traditional materials in
Automobile industry. Engineering Plastics and PP becomes a
choice by virtue of its superior versatility and cost economics.
Polymer scientists/ Chemists are building giant molecules in a
dazzling array of plastics as substitutes for metals. Though only
a few years ago selection of so called “ Engineering Plastics”
was a simple and crude choice, today there is an almost
inexhaustible list of different thermoplastics available and
Polypropylene is leading the way by virtue of its versatility in
different applications.
ENGINEERING PLASTICS
APPLICATIONS
WHY PLASTICS ?
Plastics are not simply replacement materials, whereas it is
based on technical merits, cost and other benefits makes
plastics suitable due to the following:
 ECONOMY
 WEIGHT REDUCTION
 STYING – ASTHETICS
 FUNCTIONAL DESIGN
 PROPERTIES
 REDUCED MAINTENANCE
 CORROSION AND CHEMICAL RESISTANCE
ENGINEERING PLASTICS
APPLICATIONS
Demand of Thermoplastics
Market 2002
High Performance Plastics <0, 1%
LCP, PEEK, PEI, PES, PSU
Engineering Plastics
11.5 Mil.
MT
9%
Standard Products
Mil. MT
124 Mil. MT
91%
ABS, ASA, SAN
PA
PC
POM
PBT/PET
PPO
PE
PP
PVC
PS
< 0.1
5.8
2
2
0.7
0.7
0.3
55.5
30.6
27.6
10.7
ENGINEERING PLASTICS
APPLICATIONS
PLASTICS CONSUMPTION IN A CAR - ABOUT 162 Kg
11.6% of Total Weight of the car
TYPE OF PLASTICS
Kg
TYPE OF PLASTICS
Kg
Polycarbonate (PC)
10
ABS + PC
10
Polyformaldehyde (POM, acetal)
2
6
Polymethyl methacrylate
(PMMA)
2
PP+ EPDM
18
Thermoplastics Polyesters (PET
and PBT)
2
Polyamides (PA, Nylon)
22
Others
10
Polyethelene
12
TOTAL
162
Polypropylene (PP)
29
Polyurathane (PUR)
34
Polyvinyl Chloride (PVC)
5
Acrylonitrile – butadienestyrene (ABS)
ENGINEERING PLASTICS
APPLICATIONS
Factors for Material Choice
Mechanical
Properties
Electrical
Properties
FR System
Engineering
Plastics
Thermal
Properties
Toxicology/
Safety in Use
Price
Various
e.g. Pigmentability
Processing
ENGINEERING PLASTICS
APPLICATIONS
PLASTICS IN AUTOMOBILES
INTERIOR SYSTEMS

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Cockpit Systems
Door Systems
Interiors Hard Trims
Overhead Systems
ENGINEERING PLASTICS
APPLICATIONS
PLASTICS IN AUTOMOBILES
EXTERIOR SYSTEMS




Bumper Systems (Lately integrated into Front-end
systems)
Body side claddings and cowl grills
Spoilers, capping and exterior trims
Body panels (Moving from sheet metal to plastics)
ENGINEERING PLASTICS
APPLICATIONS
PLASTICS IN AUTOMOBILES
UNDER THE BONNET SYSTEMS
 Fuel Systems – Fuel Delivery, Fuel Tanks
 Air/ Water induction System – engine cooling and climate control
systems
OTHER SYSTEMS
 Safety related parts – impact zones
 Electrical & Electronics
 Lighting Systems
 Power train & chasis systems – steering, pedal & braking system
 Soft Trim Systems – Headliners, acoustics & carpets
ENGINEERING PLASTICS
APPLICATIONS
ADVANTAGES







More complex assemblies can be easily produced as one
unit
Improved performance by reduction of vibration and noise
Improved Impact Resistance
Improved power to weight ratio
Improved aesthetics
Reduced Maintenance
No corrosion
ENGINEERING PLASTICS
APPLICATIONS
Speedo meter Housing
PP Talc Filled
Door Trim
PP Talc Filled
ENGINEERING PLASTICS
APPLICATIONS
Reflector Housing
PP Talc Filled
Hyundai Car Bumper
PP Talc Filled
ENGINEERING PLASTICS
APPLICATIONS
Seat Components
PP Unfilled
ENGINEERING PLASTICS
APPLICATIONS
Wheel Chair Base
PP Unfilled
Mixie Body
PP Unfilled
ENGINEERING PLASTICS
APPLICATIONS
Switch Frame
ABS
Instrument Holder Ford
ABS
ENGINEERING PLASTICS
APPLICATIONS
Engine Manifold – Nylon 6 GF 30
ENGINEERING PLASTICS
APPLICATIONS
Toyota Tray – Nylon 6 GF 25
ENGINEERING PLASTICS
APPLICATIONS
Honda Tray – Nylon 6 GF 45
ENGINEERING PLASTICS
APPLICATIONS
Radiator Fan
Nylon 6 GF 30
Fuel Sub Tank
Nylon 66 GF 30
ENGINEERING PLASTICS
APPLICATIONS
Timing Chain Cover & Engine Oil Filter
Nylon 66 GF 30
ENGINEERING PLASTICS
APPLICATIONS
Glove Rail
Nylon 66 GF 45
Seat Belt Anchor
Nylon 6
ENGINEERING PLASTICS
APPLICATIONS
Lever Combination Switch
Nylon 6 GF 30
Relay Box
Nylon 6 Alloy
ENGINEERING PLASTICS
APPLICATIONS
Wire Harness Connector
PBT
ECU Case
PBT GF 30
ENGINEERING PLASTICS
APPLICATIONS
Switch Base
PBT GF 40%
Actuator Case
PBT GF 30%
ENGINEERING PLASTICS
APPLICATIONS
Air Conditioner Fin
PBT GF 45%
Mirror Housing
PBT GF 30 Alloy
ENGINEERING PLASTICS
APPLICATIONS
Power Module
PPS GF/ MD 50
Alternator Parts
PPS GF/ MD 30
Neutral Start Switch
PPS GF 40 Alloy
ENGINEERING PLASTICS
APPLICATIONS
Engine Mounting parts
PPS GF 40
Lamp Socket
PPS 40
Lamp Reflector PPS
GF/ MD 60
ENGINEERING PLASTICS
APPLICATIONS
THANK YOU