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The composite rocker cover is one of the most popular global automotive applications for thermoplastics under the hood. Used as part of weight and cost reduction programs, thermoplastic rocker covers have been replacing metal parts for more than 10 years, and growth is expected to continue into other power-train applications. As the automotive industry continues to seek greater cost reductions, the integration of the thermoplastic rocker cover with other components is becoming a viable option. For example, in a recent rocker development for the Hyundai Atoz, it was discovered that there was no cost advantage in simply replacing the inexpensive pressed steel component with nylon. Although the company would benefit from the weight savings traditionally associated with the conversion from steel to thermoplastic, there was no cost driver. In order to meet target cost reductions, the rocker arm cover was integrated with the air cleaner into a single injection molded part.

The thermoplastic automotive pulley has been developed and will be commercialized to high volume production that achieves cost saving and weight reduction over other automotive pulleys in the metal and thermosetting resin by Hyundai Motor Company. Design feature incorporated in this automotive pulley allow it to be manufactured and assembled onto the water pump more efficiently in consequence of design integration with the water pump and power steering pulley. However, the harsh environment and dynamic loads that the thermoplastic pulley has to withstand required extensive CAE analysis and testing of the molded parts and the standard glass reinforced PA was selected for the application to maximize cost savings. The key aspects of the plastic automotive pulley as well as its advantage are presented.