May 01/25
Why Are Precision Automotive Plastics Key to Design Success?
In modern vehicles, plastics and polymers account for only 10% of a vehicle’s weight, but, according to American Chemistry, over 50% of its volume. Having such a high ratio of the vehicle formed out of plastic significantly helps reduce the vehicle’s mass. However, the plastic must be well-formed to ensure that it does not interfere with vehicle stability and user comfort.
Below, we explain how precision automotive plastics, such as those provided by Mayco International, offer:
- High-accuracy tolerances
- Efficient design methods
- Thinner internal walls
- Better integration with electronics and safety systems
Scroll on and discover some of the secrets of modern plastics in design and manufacturing.
Precision Automotive Plastics Boost Efficiency
These days, lightweight plastics are far lighter than many similar materials we may have used only 20 or 30 years ago. Polypropylene and nylon, for example, are far easier to use than they were several years back and are around one-seventh the mass of steel, removing mass even before optimization of each part.
Replacing large parts with plastic can save several kilograms and, simultaneously, mean that you do not need to worry about internal corrosion or other risks.
The lower mass not only allows for faster acceleration but also means that vehicles boast shorter braking distances and a reduction in tire wear, boosting safety and lowering the cost of ownership in any vehicle. At the same time, our engineers can more easily readjust the weight delta, reallocating it to areas such as structural reinforcement or soundproofing.
Injection Molding Achieves Thinner Walls
Modern manufacturing methods, such as injection molding, allow us to use plastics for many more areas of the vehicle without needing thick walls. Mayco International also has the experience to do this across large panels, allowing automotive plastics to make up more of the vehicle’s body, cutting its weight and increasing its range.
Precision Molding Optimizes Fit and Finish
With Mayco International’s expertise in precision molding, we can use advanced methods to work at such accuracy (within 0.05mm) that our vehicle parts fit together extremely tightly. These allow us to meet requirements like UL94 V0 FR much more easily, which demand a thickness of 1mm or below. Even with temperature changes where metal parts might expand and contract, you can expect them not to loosen or make noise.
We also control our injection process carefully, preventing significant flash forming and saving money on manufacturing. Then, our injection molding process means that the final parts need minimal extra finishing, allowing faster production.
During our process, we use hardware to constantly measure whether each part still fits within strict limits and predict how much the cooling process will shrink the plastic. Thus, we can compensate long ahead of time for the intricacies of plastic molding to create the most accurate productpossible.
Drive Your Development With Mayco’s Precision Plastics
During production, we prioritize lighter, stiffer, and quieter modules by leveraging our skills in automotive material innovation to get you the parts you need. Boasting sub-millimeter tolerances and a smooth design-to-shipment process, we can slash timelines and help you maintain quality using precision automotive plastics.
So, contact Mayco International today to learn what we can do for you and talk to us about our processes today.