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Since the large scale production of plastic throttle bodies in 1994 there have been a number of further introducions. However the universal adaptation of plastic for the throttle body has not yet occurred. This paper will describe design approaches and processing solutions to facilitate low cost precision manufacturing with test results of actual parts made by these approaches. Introductions: 1994 U.K. 4 cylinder engine, cable operation 1998 Germany 4 cylinder engine, cable operation 1999 U.S. 4 cylinder engine cable operation

The National Research Council of Canada, Siemens Automotive Division and Regal International Tool and Mould Inc. jointly studied the feasibility of the selective laser sintering (SLS) rapid tooling process for making mould inserts for injection moulding of plastic manifold. By overcoming a number of challenges in handling and processing large metal parts for the SLS rapid tooling process, an mould insert as big as 254 mm in diameter and 220 mm high, and weighed 47 kg was successfully fabricated. This is by far the largest metal parts ever made by the SLS process in terms of both part weight and height. The significant extension of the size limits for the SLS rapid tooling process made the technology more useful for the automotive industry, and provided a new method of rapid tooling for injection mould for plastic manifold.