BMW grille wins SPE Innovation Award

The front grille of the BMW iX electric-drive SUV provides a smart surface that enables the automaker to embed sensors, cameras and radar systems behind its decorative exterior
.

iX was one of two Innovation Award winners at the recently held Society of Plastics Engineers Central European 20th Automotive Awards
.

BMW's Dingolfing plant in Germany uses an Engel machine to mould the panels using Summerer Technologies GmbH & Co.
KG of Schechen, Germany, a 40-year-old specialist in automotive plastic glass moulding systems
.

The kidney panels are molded from Makrolon AG2677, a medium viscosity, UV stabilized, easy-release polycarbonate automotive glass material from Covestro
.
It is filled with self-healing polyurethane in a single process with integrated radome heating
.

The plasma vapor deposition (PVD) facility of Oerlikon Balzers Coatings Germany GmbH, headquartered in Bingen, Germany, creates the radar-transparent diamond-shaped metallic effect
.
This "smart surface" panel houses camera technology, radar functions, driver assistance sensor technology and heating elements
.

Composite parts reduce weight

The Mercedes-AMG GT Black Gear Carrier has received the Powertrain Innovation Award since October 2020, when series production began at the Mercedes-Benz plant in Sindelfingen, Germany
.

The part uses the FibreTEC three-dimensional free-space winding process, utilizing continuous fiber bundles from Toray Carbon Fiber Europe
Ltd.
The fibers were first impregnated with Epikote Trac 06398/Epicure epoxy resin material from Hexion GmbH, based in Iserlohn, Germany
.
This resin can withstand temperatures up to 210°C (410°F) near exhaust ducts
.

Mercedes produces 3,500 of the models a year, using two per car
.
FibreTEC3D was developed jointly by Mercedes and the ITM Institute of Textile Machinery at the Technical University of Dresden
.

The company is also using the process for robotic grippers and other production aids for A-, C-, E- and S-class cars
.

Replacing the original cast aluminum-magnesium alloy, the part is 55% lighter (0.
95kg vs.
1.
75kg) while retaining the same stiffness
.
The carrier uses 100 meters of impregnated carbon fiber wrapped around aluminum deflection/attachment points and integrated with a conventional carbon fiber reinforced epoxy composite for load bearing
.

Slotline honored for mobile innovation

The low-profile electric motor slot liner used in BMW's fifth-generation eDrive has won the Mobility Innovation Award
.
The liner increases efficiency and reduces size and weight
.

Molder Cobraplast SpA, headquartered in Turin, Italy, uses Solvay Specialty Polymers Italia's liquid crystal polymer (LCP) Xydar G930 to manufacture the part
.

Solvay also introduced the enabling technology of the second-place winner, a thin extruded KetaSpire polyetheretherketone (PEEK) insulated magnet wire from the Essex Furukawa magnet wire plant in Germany
.

BMW wins technology innovation award again

BMW's plastics processing plant in Landshut, Germany, received the Technology Innovation Award for an injection mold with integrated temperature control
.
The dielectric from the existing circuit is passed through the coarse honeycomb core of the mold, which is produced by water-assisted molding of SABIC's Stamax 20% long glass fiber reinforced polypropylene
.

Saudi Industries also earned a new Mobility No.
2 product made by Hayward, Calif.
-based molder Plastikon Industries Inc.
with Lexan 3412ECR, a halogen-free UL94-V0 flame retardant 20% glass fiber.
Reinforced polycarbonate) for the Lucid Air electric vehicle battery module housing with one-shot aluminum insert molding
.
Christian Karl Siebenwurst GmbH, headquartered in Zwickau, Germany, carried out a complex tool design, resulting in fewer production steps and a compact high-energy-density battery pack housing
.

Second place in the Chassis/Structure category was the Hyundai iX25's roof rails, made by Minth Europe Automotive DOO, headquartered in Loznica, Serbia, using Akromid B3 GF50 1GIT 50% glass produced by Compounder Akro-Plastic GmbH, Niederzissen, Germany, based in Niederzissen, Germany Fiber-reinforced nylon was gas-assisted molding using equipment from PME Fluidtec GmbH, headquartered in Ettenheim, Germany
.

Nominations for sustainable materials include Akro-Plastic's ICF "Smart Carbon Fiber" compound, which is derived from discarded CF fabric
.

LyondellBasell Co.
BV was nominated for Looppile X for body interior products
.
This is the first carpet produced by Condor Cartex BV of Genemuiden, the Netherlands, Europe's largest car carpet manufacturer, and is said to use 100% recycled PP
.
Condor can also recycle polyester-based rugs into new rugs
.