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The consumption of blow molded bumpers for passenger vehicles is increasing, particularly for small to mid-size vehicles. The performance required for bumpers in this class of vehicles varies by geographic region, as “global” vehicles are increasingly specified outside of the United States. For this reason, it is important to understand the impact performance provided by materials that could be blow molded into bumpers for this class of vehicles. This paper will compare the relative performance of polycarbonate/polybutylene terephthalate (PC/PBT) alloys vs. polyolefins for impact protection, weight, and processing performance.

Owing to OEM pressures to reduce costs and mass, improve production efficiency, consolidate parts, and eliminate secondary finishing operations, a series of new-generation fascia materials in engineering thermoplastics are being positioned to replace lower performing thermoplastic polyolefins - the current industry standard in both North America and, to a lesser extent, in Europe. Among these materials are resins capable of thin-wall molding, electrostatic conductivity, primerless adhesion to paint, the ability to eliminate paint in certain segment-specific applications, and the ability to be painted on-line with the rest of the body-in-white. These new materials are expected to have a significant impact on fascia production in both North America and Europe, as requirements for fascias change to an emphasis on lighter weight, higher structural performance, lower cost, and more efficient finishing.

Recent vehicle design trends require bumper systems to be crashworthy under more demanding circumstances, e.g. tighter package space, heavier vehicle mass, and wider rail spans. Meanwhile, pressure to reduce cost and weight of bumpers continues at a time when roles in the supplier community are changing. These factors have combined to increase the importance of optimizing bumper design and material properties for specific platforms. Materials suppliers have responded by developing a range of specialized engineering thermoplastic (ETP) resins that can help meet increasing performance requirements yet also offer the potential for improved manufacturing productivity, significant weight savings, and systems cost reductions. Material suppliers have also increased the level of technical design support provided to OEMs and 1st Tier suppliers.