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Composites are a well known solution when high performances are required. The constraints of mass production often prevent the use of high performance materials. Because low cost TPO's are combined with high performance (continuous oriented fibers) materials, the HTPC process makes possible the manufacturing of very high performance parts for low cost at high volume production. This combination of materials allows a great versatility of performance adjustable as wanted. This process confirms the possible use of composites for front beams and improved results for rear pole impact.

The use of thermoplastic for body panels in automotive industry can only be successful if the characteristics of these new materials are well known and taken into account at an early stage in development. It is the purpose of the work lead by Plastic Omnium on the Omnium System Car (OSCAR) research project to imagine the best way of using thermoplastics for the body of the front of the car. The perimeter studied includes fenders, bumpers, hood and front grille. The result is an easy to assemble modular body, weighing less and with amazing possibilities for stylists in terms of shapes and decorations.

The goal of the Omnium System Car (OSCAR) research project is to redesign the front compartment of the car using modular systems. These modules integrate new functionality, can carry various equipment and can optimize their positioning around the engine compartment. The modules developed in OSCAR are: 1 cooling module 2 front quarter modules 3 plenum cover module The functionality of these modules are described as well as the way they can be assembled on the car. Gains in terms of weight, cost and investments have also been investigated.

The vital objective for the automotive industry is to reduce costs, investments and weight of vehicles together with an increasing demand for quality, comfort and security. These ambitious goals can only be attain through an innovative approach. That’s the aim of the OSCAR project to propose a modular approach for the front compartment of the car. The project perimeter is based upon the reengineering of the body panels, technical modules gathering many functions and the system for energy absorption. The results of this study show the main objectives can be reached thanks to a better used of new materials and process.