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In recent years, the mountain rate of the Roof Rack of recreational vehicle has increased. The conventional Roof Rack employs Aluminum Leg in order to secure the strength. For lightweighting of a Roof Rack and Value Analysis, the applications to the vehicles is realized as the result of the development of the method utilizing GAS Injection (Here in after GAS Injection) which enables hollow molding of the plastic made Leg.

Recently, there has been an increase in injection molded parts formed by combining the injection process with the compression process such as vertical press molding and injection compression process technology. This combined process technology is qualitatively superior to normal injection molding and many benefits are expected. With this in mind, the automotive sunroof-shade, which is normally manufactured by the compression process with additional secondary finishing, has the potential to be use the injection compression process. This process called, “FABRIC INSERTION MOLDING (FIM)”, was evaluated.

Gas Assist Injection Molding technology is becoming a popular new or alternative method for producing various types of automotive plastic components. Qualitatively, the benefits of Gas Assist Injection Molding have been thoroughly researched and made known to the public. But, quantitatively, there are only a few applications known to the automotive industry. For our research, we constructed a Gas Assist Injection Molding set of tooling that was based on the design of a production instrument panel carrier. We compared the Gas Assist Injection Molding component and normal instrument panel carrier with the intent to observe or define the following benefits: 1. Reduction of part weight. 2. Enhance the material flow in the mold. 3. Reduce the required press clamp tonnage vs injection molding. 4. Simplification of the mold tooling. 5. Define the optimum mold conditions for selected candidates of plastic resin to be evaluated in the trials of the instrument panel.