Four auto must-sees at K2013



The biggest and world’s most famous one letter plastics trade show, “K”, is taking place October 16 to 23 in Düsseldorf. Here are four reasons to visit DuPont Stand C43, Hall 06.

1.    How to speed development time and reduce cost with CAE


For many years, crashing vehicles in a test lab and recording catastrophic-looking results was the best method to test a vehicle’s reliability and safety. This was extremely expensive and time-consuming.


Today, with the help of highly sophisticated engineering materials, computer-aided materials modeling, research and testing, the average new vehicle development process has been reduced from 4.5 years to 18 months. At DuPont, the advent of high-powered computing combined with state-of-the-art materials and highly qualified design experts has taken computer-aided simulation engineering to a new level for their value-chain partners. Simulations closely replicate real-world scenarios, resulting in quick, innovative solutions.


Come see how automakers collaborate with DuPont for expertise in materials, design and processing technologies from the earliest stages of development until the finished vehicle rolls off the manufacturer’s assembly line.


2.    Bring it to light: innovative technology and material solutions to lightweighting


Helping automakers reduce weight to lower emissions and improve fuel economy are current top DuPont priorities. At K, please stop by to see a truck oil pan of DuPont™ Zytel® polyamide resin, injection-moulded by ElringKlinger AG for Mercedes-Benz, which weighs 6 kgs—50 percent less than the aluminum component it replaces. We are also showing a developmental thermoplastic composite technology that combines strength and stiffness in structural, load bearing and crash-protection parts for body in white (BIW), suspension or underhood applications.


DuPont is collaborating with the industry to develop lighter weight components that meet performance requirements by designing first for inherently lightweight plastics. “Designing for plastic rather than using plastic in a component designed for metals requires a different approach and material data, but helps ensure all the lightweighting, strength and functional benefits are captured,” said Patrick Cazuc, automotive director EMEA, DuPont Performance Polymers.


Did you know?

It has been estimated that reducing an automobile’s total weight by just 50kg can reduce CO2 emissions by up to 5g per kilometer driven, and increase fuel economy by up to 2 percent. In engines alone, replacing metal with plastic in known engine applications can eliminate at least 11 kgs per vehicle, and double the life of parts exposed to high heat in turbocharged engines. Apply that to the 83 million engines scheduled for production in 2013, and the need for over 1 billion liters of fuel, or almost 10 million barrels of crude oil, can be eliminated.


3.    Integrated jounce bumper system hits European roads


Fiat adopts an integrated jounce bumper system made of DuPont™ Hytrel® thermoplastic elastomer on its Punto model, that integrates several components into one to deliver better performance and a lower system cost. The suspension’s component is the result of an integrated design, materials and processing approach by a team from DuPont, Fiat, Insit, and Ossberger. Together they developed a novel approach that improves driving dynamics and passenger comfort, essential in Fiat vehicles.


Several other OEMs have also tested the new design on a variety of vehicles over tens of thousands of kilometers without any behavioral issues. The tests have proven that the new design delivers similar performance to PUR, but with lower part damage. Indeed, after traversing 3,000km of cobblestoned roads, the jounce bumper made of Hytrel® resin exhibited less than 3% permanent deformation, far below the industry target of 10%.


4.    Investments in advanced materials


DuPont is focused on reducing dependence on fossil fuels, with investments in advanced materials and expert application development, especially in lighter weight alternatives to metals that can withstand the intense heat, aggressive chemicals and constant high pressures in modern automotive engines. The goal is to significantly reduce component weight without compromising structural performance and sustainability, to help automakers reduce total vehicle weight, cut CO2 emissions, and build a secure energy future. Much of the developmental work is carried out at one of 11 DuPont Innovation Centers worldwide, connecting customers, strategic partners and academics with more than 10,000 DuPont scientists and engineers. Four of these centers are focused on the automotive industry, where the company’s global development teams work on five innovative pathways to lightweighting, engine efficiency, bio-based solutions, electrification and alternative drive systems.


Please come challenge our science to deliver cost and weight savings on your next development program. Not planning to attend? Connect here.