June 27, 2006
Putting Science to Work: DuPont Auto Lighting Technology Enhances Designs, Reduces Cost
Automotive headlamps, a key component of vehicle styling, can now be manufactured more cost effectively, thanks to DuPont materials science know-how and application development capabilities. The company has developed a new approach that has yielded up to 40 percent cost savings compared to traditional manufacturing methods for headlamp bezels, the extension surrounding auto headlamps.
Attractive new car designs incorporating front-end contours put headlamps very close to trim rings, where temperatures rise to about 150 degrees Celsius (302 degrees Fahrenheit). Traditional materials that can withstand these temperatures require painting or are considerably higher priced. DuPont’s new solution, using a new highly engineered grade of DuPont™ Crastin® PBT plus design and processing support, enables direct metallization of the trim ring and enables the newest distinctive designs to be molded much thinner.
“DuPont is committed to delivering innovative new products that meet market needs. A key requirement in the auto industry is continuously reducing costs. The global team working on this innovation leveraged its deep market knowledge and applications development expertise to achieve this cost savings approach,” said Keith Smith, vice president and general manager, DuPont Engineering Polymers.
Millions of 2007 model year vehicles globally, including the Ford Focus, Chevrolet HHR, Lincoln Navigator, several BMW models, Nissan Titan and Skoda Octavia, incorporate new direct metallization technology that taps the inherent heat resistance and thermal stability of Crastin® PBT. DuPont technical support optimized design, tooling and machinery to enable the direct metallization and ensure high yields for significant cost savings.
