Volvo Integrated Front End Assembly

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Volvo Integrated Front End
Made by CPI’s Advantage™ Technology

Reduced Part Weight
Greater Impact Resistance
Significantly Reduced Part Cost
Uniform Glass Content in Ribs
Improved Surface Finish
On-line Recycling

CPI was recently asked by a major European auto manufacturer to produce a specially designed front-end module, using our patented Direct Melt Phase Forming technology. During vehicle assembly the module is attached to the fenders, grille and radiator. It also incorporates the hood safety latch. The CPI product was then compared with the same part produced by SMC, GMT (Glass Matte Thermoplastic)/Injection molding methods.

Volvo Integrated Front End
Made by CPI’s Advantage™ Technology

Prior to the CPI test, the GMT was the leading contender for module production. However, the customer wanted to learn if advertised advantages of the CPI process really existed.

Molding was done over a period of several days with the modules tested after each run. Impact resistance, tensile strength, surface appearance and moldability were the important characteristics considered.

Performance Advantages Of The CPI Product Were Quickly Demonstrated

The CPI process provided higher glass content in the vital ribbed areas of the module. (Ribbing had been designed out of the production mold because of inconsistent glass content in these areas when molded in GMT.) Testing showed no less than 35% glass content in each CPI run. The GMT module showed negligible glass content in the ribbing when subjected to the same tests.
The CPI process also delivered greater impact resistance, exceeding specified minimums with each run. The CPI product then passed the maximum test level the fixture could produce. The GMT part, one pound heavier, failed at the same maximum test level.
Because of the module’s importance as a safety catch for the vehicle hood, additional strength tests were performed, first to minimums and then to failure. A special test fixture simulating in-car conditions was used. In all cases the CPI module exceeded minimum specifications, and then went on to levels almost double the minimum. The “best case” GMT molding reached no more than marginal acceptance levels.

ALL CPI test results proved more consistent than marks posted by other materials, yielding lower standard deviations.

And CPI demonstrated even more advantages...

Processing Required 25% Lower Tonnage
Equal or Even Lower Cycling Times were Achieved
Acceptable Performance Levels with Lighter Part Weight
Less Part-to-Part Weight Variation
Improved Surface Finish, Reduced Warpage, a “Stiffer” Molding
Reduced Surface Glass Exposure ... Safer Handling During Assembly
On-line Recycling... Especially Important to the European Market

This auto manufacturer now is convinced that the patented CPI Direct Melt-Phase Forming technology fulfills its advertised claims. And…the customer confirmed another most important CPI advantage, substantial reduction of production costs.

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