2019 SPE Auto Innovation Awards Showcase Breakthroughs in Automotive Plastics

The 49th annual Automotive Innovation Awards Competition, organized by the Society of Plastics Engineers (SPE) Automotive Division, was held on November 6 at a gala in Livonia, Michigan. The event honored nine standout innovations that demonstrate the expanding role of plastics in automotive design, engineering, and sustainability.

As the longest‑running and largest contest in the automotive and plastics sectors, the competition attracts submissions from OEMs, tier‑1 suppliers, and polymer manufacturers. Teams present a part, system, or full vehicle that they believe represents the “Year’s Most Innovative Use of Plastics.” The ceremony typically draws more than 700 engineers, executives, and media representatives, and the proceeds support SPE’s educational and technical outreach initiatives.

For this editor, along with colleagues Jeff Sloan (Composites World) and Natalia Ortega (PT Mexico), serving on the Blue‑Ribbon judging panel was a privilege. Below is a concise overview of the nine winners, beginning with the Grand Award winner in the Body Exterior category.

Body Exterior / Grand Award Winner – Composite Pickup Box

Innovation: First pickup bed constructed from carbon‑reinforced thermoplastic composite.

Impact: Saves 62 lb (28 kg) in weight, offers superior impact resistance, and eliminates the need for a traditional bedliner—an additional 40 lb (18 kg) saved. The design incorporates molded functional dividers, motorcycle tire pockets, and a deeper draw that increases cargo capacity. Full recyclability and selective scrap reuse on the vehicle complete the life‑cycle benefits.

• OEM: 2020 GMC Sierra LD FST (General Motors)
• Tier Supplier/Processor: Continental Structural Plastics
• Material Supplier/Toolmaker: Teijin Ltd.; Paragon D&E, Model Die & Mold, Inc.; Altron Automation; Legacy Industries
• Material/Process: Sereebo A235Y carbon‑fiber‑reinforced nylon‑6 sheet; compression molding

Additive Manufacturing – Sunglass Bin

Using 3‑D printing, a single tooling insert replaced two conventional lifters, enabling a deeper, more complex pocket that can be molded without hotspots, warpage, or demolding issues. The new design improves customer satisfaction, reduces cycle time, cuts molding scrap, lowers tooling maintenance, and enhances dimensional stability.

• OEM: 2020 Ford Explorer SUV (Ford Motor Co.)
• Tier Supplier/Processor: Methode Electronics, Inc.
• Material Supplier/Toolmaker: Celanese Corp.; RGM Tooling Consultants, Inc.
• Material/Process: Celstran PP‑GF20‑02 LFT‑PP; injection molding; 3‑D printed H13 steel

Aftermarket & Limited‑Edition Vehicles – Additively Manufactured Components

For the 2020 Jaguar XE SV Project 8 supercar, 19 parts were produced on a single printer platform, eliminating $123,000 in tooling costs and reducing storage and maintenance expenses. The parts exhibit superior bonding adhesion, meet paint adhesion tests, and are printed simultaneously as a kit for scalable production.

• OEM: 2020 Jaguar XE SV Project 8 (Jaguar Land Rover)
• Tier Supplier/Processor: HP Inc.; Jaguar Land Rover
• Material Supplier/Toolmaker: HP Inc.; DyeMansion GmbH
• Material/Process: HP High‑reusability PA 12; HP Multi‑Jet Fusion

Body Interior – Integrated Button Carrier Modular Strategy

Replacing a 70‑part assembly with a single injection‑molded carrier made from MIC PC/ABS reduces part count to 17, delivering $7 savings per vehicle and $1.42 million program savings in tooling and testing. The design eliminates button binding, improves BSR performance, and enhances headliner fit. Two patents have been filed, one granted.

• OEM: 2020 Ford Explorer/Aviator/Corsair SUVs
• Tier Supplier/Processor: Methode Electronics, Inc.
• Material Supplier/Toolmaker: The Materials Group; RGM Tooling Consultants, Inc.
• Material/Process: Opticarb 8085SE PC/ABS; injection molding

Chassis / Hardware – Rear‑Differential Front Bracket

An injection‑molded bracket made from 50% glass‑reinforced nylon‑66 replaces a die‑cast and machined aluminum bracket. The composite material is 30% lighter, saves $1 per vehicle, and provides tenfold higher damping, improving NVH performance while meeting packaging constraints. Corrosion is eliminated, and long‑term tooling costs are reduced.

• OEM: 2020 Jeep Cherokee SUV (FCA NA LLC)
• Tier Supplier/Processor: Boge Rubber & Plastics
• Material Supplier/Toolmaker: BASF Corp.
• Material/Process: Ultramid A3WG10CR 50% GR‑Nylon 66; injection molding

Environmental – 100% PCR Carbon Canister Housing

Recycling polypropylene (PP) from used automotive carpeting, this first fully post‑consumer‑recycled (PCR) PP canister housing replaces virgin PP, cutting material cost by 25% without compromising performance. The part is now deployed across more than 20 Ford programs worldwide.

• OEM: 2019 Ford Mustang (Ford Motor Co.)
• Tier Supplier/Processor: Delphi Technologies PLC; MGS Mfg. Group
• Material Supplier/Toolmaker: Wellman Advanced Materials; MGS Mfg. Group
• Material/Process: EcoLene PP8004‑BK1 20% GR‑PP; melt compounding & injection molding

Materials – Glass Wool‑Reinforced Composites for Scratch Resistance

Replacing talc, whiskers, and fiberglass with crushed glass‑wool and sand derived from reclaimed PIR building insulation improves long‑term scratch resistance and dimensional stability in injection‑molded PP interior trim panels. Filler content is reduced by 5%, resulting in lighter, less costly parts that also mitigate warranty claims.

• OEM: 2017 Hyundai Elantra sedan (Hyundai Motor Co.)
• Tier Supplier/Processor: Seoyon E‑Wha
• Material Supplier/Toolmaker: Daehacom Co., Ltd.; Seoyon E‑Wha
• Material/Process: SW920 SA glass‑wool‑reinforced PP; injection molding

Powertrain – Transmission Gear Shroud

Replacing steel covers with injection‑molded TPC‑ET eliminates the need for transmission fluid infiltration, lowers hydraulic effort, and boosts pump efficiency. The new design reduces cost by 22%, cuts weight by 65%, and improves NVH performance. Snap‑fits join the cover and base permanently, ensuring a durable seal.

• OEM: 2017 Ford F‑150 pickup (Ford Motor Co.)
• Tier Supplier/Processor: Stackpole International; MacLean‑Fogg Co.; Engineered Plastics Components Inc.
• Material Supplier/Toolmaker: DuPont de Nemours, Inc.; Gibson Automation
• Material/Process: Hytrel 8238 TPC‑ET; injection molding

Process / Assembly / Enabling Technologies – Rear Bumper

The first pultruded curved bumper beam uses a radius‑pultrusion process to produce a hollow carbon‑fiber‑reinforced polyurethane/acrylate resin beam with an integral tow‑hook mounting. This geometry matches vehicle styling and package space while cutting mass by 4.9 lb (2.2 kg) compared to MIG‑welded aluminum. 3‑D printing generates mandrels that maintain the hollow interior during fabrication.

• OEM: 2020 Chevrolet Corvette (General Motors)
• Tier Supplier/Processor: Shape Corp.
• Material Supplier/Toolmaker: SGL Carbon SE; VectorPly Corp.; Scott Bader Co. Ltd.; Thomas GmbH + Co. Technik + Innovation KG
• Material/Process: Crestapol 1250 PUR‑acrylate reinforced with CF; radius‑pultrusion

These nine innovations underscore the dynamic synergy between automotive engineering and advanced plastics, paving the way for lighter, more durable, and sustainable vehicles.