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As a result of the impending European End-of-Life Vehicle Directive and other business drivers such as supply-chain information requests, many tier one automotive suppliers have begun implementing Design for Environment (DfE). However, there is no standard way of implementing DfE and few guidelines for designing successful DfE programs. Companies can begin by selecting a case study design to gain experience, understand the challenges and determine the best method for implementing DfE. As part of a partnership of public and private sector organizations, Magna International and Five Winds International, carried out a DfE case study. The case study was implemented using a comparison of an existing door panel and a DfE concept panel at Magna International. The process involved utilizing several DfE tools, including checklists and LCA (Life Cycle Assessment), to determine the key environmental aspects of the two designs.

Striving continuously in the automotive industry to further reduce costs and improve quality, Low Pressure Molding (LPM) has shown to be a system to achieve these goals. Melt Compression Molding (MCM) is the latest derivative of Low Pressure Molding technologies. Compared to conventional LPM processes, MCM reduces the melt pressure in the mold by eliminating the typical hotrunner system. This makes it possible to use cheaper and less specialized raw materials. The paper describes the principles of MCM, its applications and machine requirements.