The winners of the SPE Automotive Innovation Award

Winner: Third-row seatback
Category: Body Interior
OEM make: 2021 Toyota Motor Corp.
Model: Toyota Sienna
Tier supplier/processor: Toyota Boshoku Corp./Flex-N-Gate Corp.
Material supplier/toolmaker: BASF Corp./Concours Technologies Inc.
Material: Ultramid B3ZG7 CR PA 6

A 16-piece steel assembly was replaced with a single, shoot-and-ship polyamide injection-molded assembly for this third-row seatback that reduced mass by 30% and cost by 15%. The innovation delivered a two-fold improvement in crash performance and took 63% less effort for occupants to raise the seat to its upright position, eliminating the need for a seat motor.

The industry’s first fully plastic freestanding seatback offers very good energy absorption without the need for metal support brackets. A new 35% short-glass, impact-modified PA6 resin was developed for this sequentially injected application.

Winner: Wiring harness clip
Category: Environmental
OEM make: 2021 Ford Motor Co.
Model: Ford Bronco Sport
Tier supplier/processor: Lear/ HellermannTyton North America
Material supplier/toolmaker: DSM/HellermannTyton North America
Material: Akulon RePurposed PA6

These glass-fiber-reinforced recycled polyamide 6 wire-harness clips are injection molded from 100% post-consumer recycled ocean plastics. Ghost gear (fishing net) is collected by fishermen in the Indian Ocean and Arabian Sea, providing jobs, more sustainable livelihoods, and healthier marine life.

The material provides comparable performance to petroleum-based prime resin at 10% cost savings, lower energy, improved supply-chain stability, and life-cycle benefits. No tooling changes and minimal process changes were needed for this drop-in change.

Winner: Composite roof receivers
Category: Materials
OEM make: 2021 Stellantis Jeep Wrangler
Model: Jeep Gladiator
Tier supplier: Stellantis
Material supplier/toolmaker: Mitsubishi Chemical Advanced Materials/Maple Mold Technology
Material: KyronMAX S-4330 PPA with 30% USCF

Six brackets for removeable hardtop and soft-top roofs were converted from investment cast steel to 30% ultrashort carbon fiber (USCF) reinforced polyphthalamide (PPA) injection-molded components, providing comparable part strength while reducing cost by 38% and mass by 79%.

Powder coating was eliminated, and scratch and mar improved, while achieving a weatherable, Class A finish that allowed for mid-program replacement and backward-service compatibility.

The USCF composite molds like neat polymer, but outperforms long-fiber thermoplastic (LFT) materials, is recyclable, and exhibits a lower carbon footprint than metal/alloy parts. Direct-drop valve gates and T-nut fasteners also were key enablers.

Winner: Thick lightbar development
Category: Process/Assembly/Enabling Technologies
OEM make: 2021 General Motors Co.
Model: Cadillac Escalade
Tier supplier/processor: Valeo Lighting Systems
Material supplier/toolmaker: Covestro/Windsor Mold Group
Material/process: Makrolon LED PC/multi-cavity, multi-shot injection molding

This 780-mm-long and 18-mm-thick transparent-red light blade for rear taillamps delivers a unique, homogeneous lit appearance. Keys to making the patented application work were advanced simulation tools for design and functional optimization and warpage control; complex runners and parting lines, shutoff valves, and multi-shot injection process control; plus a custom-formulated optical-grade of PC that helped manage quality, cost, and molding capacity and met all legal rear-lighting requirements.

Winner: Multi-material rear leaf spring
Category: Chassis/Hardware
OEM make: 2021 Ford Motor Co.
Model: Ford F150
Tier supplier/processor: Rassini Suspensiones/Rassini Suspensiones, SGL Carbon
Material suppliers: Hexion Inc., SGL Carbon
Materials: Epikote TRAC 06150 resin; Epikure TRAC 06150 curing agent, Heloxy TRAC 06805 additive

This hybrid rear leaf spring, which won the Grand Award selected among the winners of all of the categories, combines a high-strength steel main pack plus a high-pressure resin transfer molding (HP-RTM) fiberglass-reinforced epoxy composite helper.

It reduces mass by 30% while providing the same stiffness and durability as a conventional steel leaf spring system. Additional benefits include increased payload capability, lower part count, decreased interleaf friction, smoother engagement, lower noise, and a lower carbon footprint.

Winner: Integrated tether system
Category: Additive Manufacturing
OEM make: 2021 Ford Motor Co.
Model: Ford Maverick
Tier supplier and processor: IAC Group

In an industry first, customers can select, download NFTL files, and 3D print their own swappable accessories — cupholders, trash bins, etc. — that fit in storage slots of their vehicle across the entire Maverick series.

Initial designs were developed by Ford and its supply teams, but future iterations could be suggested by customers. A variety of printer types and suggested materials can be used. This provides customers with flexible, customizable storage and use features or the option to maximize cabin space while avoiding significant tooling investment.