2019 SPE Blue Ribbon Automotive Innovation Award Winners – Highlights of Automotive Plastics Breakthroughs

Across nine categories, the 49th annual Society of Plastics Engineers Automotive Division’s 2019 Blue Ribbon Automotive Innovation Awards celebrated groundbreaking uses of plastics in the auto industry. Thermoplastics, thermoplastic composites, and additive manufacturing dominated the field, with the latter featuring again in its own and aftermarket categories. Below is a concise overview of each winner, starting with the overall Grand Award, which also claimed the Body Exterior title.

BODY EXTERIOR – Composite Pickup Box

GM’s 2020 Sierra LD FST pickup showcases the first carbon‑reinforced thermoplastic composite pickup box. Teijin’s Serrebo A235Y carbon‑fiber‑reinforced nylon‑6 sheet, produced by Continental Structural Plastics, cut 62 lb (28 kg) of weight, delivered superior impact resistance, and its unpainted UV‑stable surface eliminated the need for a bedliner, saving an additional 40 lb (18 kg).

ADDITIVE MANUFACTURING – Sunglass Bin

Ford introduced a single, 3‑D‑printed tooling insert that replaced two conventional lifters, enabling a deeper, heavier undercut in the sunglass stowage bin for the 2020 Explorer SUV. Using Celanese’s Celstran PP‑GF20‑02 LFT‑PP with Methode Electronics and an H13 steel insert from RGM Tooling Consultants, the design improved customer fit, reduced cycle time, and lowered molding scrap without switching to a pricier resin.

AFTERMARKET & LIMITED EDITION – Multiple Additive‑Manufactured Components

For the 2020 Jaguar Land Rover LXE SV Project 8 supercar sedan, 19 parts were printed on a single HP Multi‑Jet‑Fusion platform using HP’s high‑reusability nylon‑12. This eliminated a $123,000 tooling investment, cut storage and maintenance costs, and delivered better bonding adhesion and paint durability.

BODY INTERIOR – Integrated Button Carrier Modular Strategy

Ford’s 2020 Explorer, Aviator, and Corsair SUVs adopted a single modular button carrier that integrates mechanical, lighting, electrical, and safety functions. Made from The Materials Group’s MIC Opticarb PC/ABS via Methode Electronics, the redesign reduced part count from 70 to 17 per vehicle, saved $7 per unit, and generated $1.42 million in program savings. Two patents have been filed, one granted.

CHASSIS/HARDWARE – Rear‑Differential Front Bracket

Boge Rubber & Plastics replaced a diecast aluminum bracket in the 2020 FCA Jeep Cherokee with an injection‑molded part made from BASF’s Ultramid A3WG10CR (50 % glass‑reinforced nylon‑66). The composite bracket is 30 % lighter, cuts $1 per vehicle in direct costs, offers tenfold higher damping, and eliminates corrosion, all while fitting existing packaging.

ENVIRONMENTAL – 100% PCR Carbon Canister Housing

Delphi Technologies’ 2019 Mustang used a 100 % post‑consumer‑recycled (PCR) PP canister housing. Wellman Advanced Materials recycled PP from carpet into EcoLene PP8004‑BKI 20 % GR‑PP, reducing costs by 25 % without compromising performance and enhancing sustainability. The housing is now rolled out across 20+ Ford programs worldwide.

MATERIALS – Glass Wool‑Reinforced Composites for Scratch Resistance

Daehacom’s SW920 SA glass wool, derived from reclaimed building insulation, replaced talc, whiskers, and fiberglass in Hyundai Elantra interior trim panels. Injected by Seoyon W‑Wha, the material boosts mechanical properties, reduces filler by 5 %, and improves long‑term surface finish, potentially lowering warranty claims.

POWERTRAIN – Transmission Gear Shroud

In the 2017 Ford F‑150, a new gear shroud made from DuPont’s Hytrel 8238 TPC‑ET replaced steel covers. The design eliminates the need to push gears through fluid, improving pump efficiency and fuel economy. Costs dropped 22 %, weight fell 65 %, and NVH performance improved.

PROCESS/ASSEMBLY – Rear Bumper

GM’s 2020 Corvette features the industry’s first pultruded curved bumper beam, crafted with Shape Corp’s radius‑pultrusion process using SGL Carbon’s CF and Scott Bader’s Crestapol 1250 PUR‑acrylate. The hollow beam cuts 4.9 lb (2.2 kg) of mass versus MIG‑welded aluminum, meets low‑speed crash requirements, and is assembled with an integral tow‑hook mounting.