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Recently there has been a strong move to develop technologies aimed at reducing injection molding clamp forces. While these processes claim lower clamp pressures, “low pressure molding,” correctly defined, is much more versatile. Not a single action, but multiple functions.

Headliners are large parts that must be lightweight, sound absorbent and sturdy enough to carry a complement of other interior components as well. And as the dashboard becomes loaded with more and more technologies, there is a drive to spread some of that complexity over the rest of the interior of the car. Automotive headliners offer an opportunity for slashing vehicle production costs by integrating components and functions in a one-step operation. The headliner is the ideal candidate not only to accept sun visors, lighting systems and hand grips, but also garage door openers, cellular telephones and audio speakers. This paper will discuss the use of low pressure injection molding as a way to reduce headliner production costs while expanding functionality. It will also examine the equipment requirements and the implications of this process for designers and manufacturers of vehicle headliners.

Low pressure molding is a radical departure from conventional injection molding. It enables designers to combine totally different materials in a single step, to produce parts with multiple functions. By taking this approach, manufacturers can reduce assembly labor, material cost, and part weight while improving their competitive position. But because it is so different, designers and processors are required to re-think their approach to product design and manufacturing. A more integrated, systems approach is required and this demands a willingness to look at new technologies. Already, textile and film suppliers are gearing up to meet the demands of new process technologies, such as low pressure molding.