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Current plastic intake manifolds are manufactured using the injection molding process. In this paper, thermoforming is explored as an alternative to injection molding for making intake manifold shells, which can then be joined by one of the welding techniques used for thermoplastic materials. The investigation reported here includes press-forming experiments of a simple bowl shaped shell and subsequent welding experiments to join these shells.

Engine control technology in the United States market has evolved from the complex multipoint fuel injection systems of the 70's to the more popular and less costly single point injection systems of the 80's, one of which won the 1983 Motor Trend Car of the Year Award. Integration of single point fuel injection electronics and spark timing into the throttle body housing now offers a cost effective engine control package with substantial reduction in wiring harness complexity. Thick film circuit technology makes this concept practical in the engine compartment environment. A prototype system was built which demonstrated the feasibility of integrating electronics into an engine mounted assembly. This technology is applicable to a broader range of integrated engine systems including ignition control. Engine mounted electronics can also be used for other applications such as diesel engines.