Ford 'Escape' Weight, Boost Fuel Economy With MuCell Injection Molding
Can a simple plastic injection molding process save weight of whole automobile significantly? However Ford is planning to incorporate a technology based on injection molding in manufacturing of Instrument panel of its cars. The technology developed by MIT scientists called MuCell® way back in 1995 is about to make re-enter in the automobile industry with the introduction of Ford Escape.
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It is not the first time that MuCell is thought of a manufacturing process for plastic components. Earlier it has been used in valve seat covers of many of the European cars. It is however the first time that the molding process will be used in a vehicles instrument panel.
#-Link-Snipped-# of panel by around one pound. It might not account for a significant amount of weight however the ingenuity of the process lies in the strength of the panel. Normally it is observed that the strength of plastic falls drastically with the reduction in weight of the component. MuCell removes any such possibility with the use of a Microcellular foaming phenomenon seen in it. The process makes a highly controlled use of molding gases like N<sub>2 </sub>and CO<sub>2</sub>.  Hence we can determine the amount of solid weight which can be displaced by the pores formed by gas.
Naturally as we are talking about the weight saving done by employing this technology, the factor of fuel saving also comes into picture. Not only this, it also saves the overhead cost and the time required to make the plastic boards as compared to the other molding techniques. As per a rough estimate by the auto company MuCell enable them to save $3 per vehicle, takes about 85% time to complete the job as compared to other techniques and also a reduction of 45% in molding clam tonnage is observed.
Ford motor co. has always tried to make innovations it its vehicles, may it be the #-Link-Snipped-# or the #-Link-Snipped-#. Recently Ford received Most Innovative Use of Plastic award in a competition organized by Society of Plastic Engineers.
It remains to be seen how much driving experience and convenience Ford Escape can give to customers. The overall performance cannot be determined by the instrument panel only. MuCell which is earlier used in Heating, ventilating and air conditioning systems might prove to be beneficial if it can be incorporated for manufacturing other plastic components.
#-Link-Snipped-#
It is not the first time that MuCell is thought of a manufacturing process for plastic components. Earlier it has been used in valve seat covers of many of the European cars. It is however the first time that the molding process will be used in a vehicles instrument panel.
#-Link-Snipped-# of panel by around one pound. It might not account for a significant amount of weight however the ingenuity of the process lies in the strength of the panel. Normally it is observed that the strength of plastic falls drastically with the reduction in weight of the component. MuCell removes any such possibility with the use of a Microcellular foaming phenomenon seen in it. The process makes a highly controlled use of molding gases like N<sub>2 </sub>and CO<sub>2</sub>.  Hence we can determine the amount of solid weight which can be displaced by the pores formed by gas.
Naturally as we are talking about the weight saving done by employing this technology, the factor of fuel saving also comes into picture. Not only this, it also saves the overhead cost and the time required to make the plastic boards as compared to the other molding techniques. As per a rough estimate by the auto company MuCell enable them to save $3 per vehicle, takes about 85% time to complete the job as compared to other techniques and also a reduction of 45% in molding clam tonnage is observed.
Ford motor co. has always tried to make innovations it its vehicles, may it be the #-Link-Snipped-# or the #-Link-Snipped-#. Recently Ford received Most Innovative Use of Plastic award in a competition organized by Society of Plastic Engineers.
It remains to be seen how much driving experience and convenience Ford Escape can give to customers. The overall performance cannot be determined by the instrument panel only. MuCell which is earlier used in Heating, ventilating and air conditioning systems might prove to be beneficial if it can be incorporated for manufacturing other plastic components.
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