Check out the winners of SPE Automotive Innovation Awards 2023

Mega Bin / Frunk

Grand Award and category: Body Interior

• OEM Make & Model: 2024 Ford Motor Co. Ford F-150 Lightning

• Tier Supplier/Processor: Cascade Engineering

• Material Supplier/Toolmaker: Celanese Corp. / Commercial Tool Group

• Material/Process: Celstran PP-GF40 AD3004 (PP-LFT 40%) / Injection Molding

Currently the industry’s largest, the large Class A composite frunk reduced mass by 48% and productivity was increased with 37% cycle time reduction, cost and environmental burden of paint eliminated, seal interfaces improved, secondary routering of holes is not needed and the frunk can be fully recycled at end of life.

Hybrid Battery Interconnect Board

Category: Aftermarket and Limited Edition/Specialty Vehicles

• OEM Make & Model: 2024 General Motors Co. Chevrolet Corvette E-Ray

• Tier Supplier/Processor: Sun Microstamping Technologies

• Material Supplier/Toolmaker: BASF Corp. / Sun Microstamping Technologies

• Material/Process: Ultramid B3UG4 PA 6 / Vertical Clamp Parting Line Injection Rotary Molded – Insert Overmolding

This patented part features small and delicate metal current collectors, bus bars, and sensing lines in a very compact design to fit in limited packaging space. The 20% GF/PA6 grade is compatible with snapfits, heat staking ultrasonic welding and adhesive bonding. The material is also heat stabilized and flame retardant.

Thermoplastic Splitgate

Category: Body Exterior

• OEM Make & Model: 2023 Rivian LLC Rivian R1S

• Tier Supplier/Processor: Magna International

• Material Supplier/Toolmaker: Advanced Composites, Inc. / Tycos Tool & Die Co.

• Material/Process: LGF-PP & TPO / Injection Molding

As the world’s first all-thermoplastic split gate rear-closure system, the complex, deep draw (>80mm) design offers improved perceived quality at lower mass, NVH, and cost vs. metals, and is offered in a 2-tone execution.

Battery Disconnect Unit

Category: Electric and Autonomous Vehicle Systems

• OEM Make & Model: 2023 General Motors Co. GMC Hummer EV

• Tier Supplier/Processor: Lear Corporation

• Material Supplier/Toolmaker: BASF Corp. / Lear Corporation

• Material/Process: Ultramid 66 H2 G25 V0KB1 and Ultradur B4450G5 HR / Injection Molding

Two BDUs have been integrated into a single system supporting two 400V systems, enabling fast and safe recharging of EVs. The meter-long parts offer improved thermal management and reduced component mass. Two UL94 V0 halogen-free materials replaced die-cast aluminum with superior physical properties and ease of processing.

Battery Module Side Plates

Category: Materials

• OEM Make & Model: 2024 General Motors Co. Chevrolet Corvette E-Ray

• Tier Supplier/Processor: Novares Group

• Material Supplier/Toolmaker: RTP Co. / Liberty Molds, Inc.

• Material/Process: RTP 299 K X 138337 E BLACK / Injection Molding

The patented side plates uses RTP 299 K X 138337 E BLACK PARA material instead of metals, allowing extremely flat parts with high dimensional accuracy, stiffness and strength. The high-modulus, creep-resistant FR polymer eliminated the need for compression limiters and electrical isolation films, but can withstand extreme pressures.

Seat Module

Category: Process/Assembly/Enabling Technologies

• OEM Make & Model: 2024 Toyota Motor Corp. Toyota Grand Highlander

• Tier Supplier/Processor: Hi-Lex Corp.

• Material Supplier/Toolmaker: NA / Hi-Lex Corp.

• Material/Process: NA / Injection Molding

This patented injection molded module features to control cables and reduce components and effort at the seat manufacturer. Cables are delivered to the Tier 1 pre-routed on the module plate, eliminating typically used components such as brackets and cable ties.

Intumescent Terminal Covers

Category: Safety

• OEM Make & Model: 2023 General Motors Co. Cadillac Lyriq & GMC Hummer

• Tier Supplier/Processor: Auto-Kabel Group/ Molded Precision Components

• Material Supplier/Toolmaker: Pyrophobic Systems Ltd. / NA

• Material/Process: Lithium Prevent 200 PVC / Injection Molding

The specially formulated flexible and intumescent PVC prevents arcing during thermal runaway events. The high-temperature, high-voltage insulator maintains high dielectric strength, reducing arcing risk and ignition of gases and forms a structured char barrier.

One-Piece Thermoplastic Frunk

Category: Sustainability

• OEM Make & Model: 2024 Ford Motor Co. Ford Mustang Mach E

• Tier Supplier/Processor: IAC Group

• Material Supplier/Toolmaker: Advanced Composites, Inc. / HS Inc.

• Material/Process: ADX8327 20% PCR TPO / Injection Molding

This is the first time a 20% PCR recycled material has been used in a color-matched, MIC, Class A structural frunk application. Compared to virgin TPO, it is a more sustainable grade with slightly lower density and better impact at -15°C. Reducing component count from 6 to 1, it saves 3kg of mass, increases cargo volume and functionality, improves water management, and saves an estimated 1,125 tons of CO2 annually. The PCR content is sourced from yogurt cups and packaging materials.