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Steadily encroaching on metal and other materials in more and more challenging applications, plastics used in products as diverse as tractor hoods and running boards were showcased in the Society of the Plastics Industry's (SPI; Washington, DC) Structural Plastics Awards (March 21-23, 2004, Charlotte, NC). Bemis Mfg. (Sheboygan Falls, WI) took home three awards for a John Deere tractor enclosure, tractor top hood, and front-end for an off-road Gator vehicle.
Top honors, however, went to a cowl for a four-stroke outboard boat engine entered by Mercury Maringe (Fond Du Lac, Wi) and molded by Bemis, which won the Conference and People's Choice awards. The 11.3 lb (5.13 kg) engine cover is said to be the largest injectin molded nylon part ever produced. Replacing an SMC cowl, the nylon component was scoop shaped and measured 851 by 582 mm, with a depth of 417 mm. It weighed 3 lb (20%) less than its predecessor and was reinforced by 33% glass.
All told, the competition featured 62 parts, 36 of which were injection molded, along with RIM, blowmolded, rotomolded, and extruded entries. Gas-assist was used in 10 parts, and direct long-fiber compounding was applied in several, including a running board for the Ford F-250/350 trucks, molded by Composite Products, Inc. (Winona, MN). Using long-fiber technology, the PP part started as an extruded log with glass strands providing reinforcement. It was then transfer molded into one part that ultimately combined 43 components into one and reduced overall weight by 30 lb.
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