Solvay company produces integrated ventilation system elements (including the air-conditioning ducts under the hood).

Sheets made of Polyvinyl Chloride(PVC) -ABS, PVC foam or polyolefins suitable for thermoforming are used to mold the dashboards and door panels.

The instrument panel (IP) system on the 1995 Lincoln Continental contains parts molded from eight different engineering resins made by GE Plastics. Of these, particular note is given to CYCOLAC® GHT4400 ABS resin from GE Plastics, which was specified by Ford Motor Company for the structural air conditioning (AC) duct, providing a substructure for the overall IP system. The AC duct represents the first commercial automotive application of a passive restraint one-piece (structural) IP system for GE Plastics.

The largest single component in the Continental's IP system, the AC duct weighs 11 pounds and supports the IP substrate, air management system and knee bolster reaction surfaces. The CYCOLAC resin specified for the application is an acrylonitrile butadiene styrene (ABS) polymer selected for its high heat resistance and dimensional stability over a wide temperature range. The duct provides a rigid substructure for the IP assembly, resulting in reduced noise and squeaks coming from the IP.

The structural IP concept was developed to meet the many challenges of parts consolidation, weight reduction, design for manufacturing and system cost savings. The one-piece molded duct actually replaces 17 functional metal parts, helping to reduce weight, assembly time, inventory and material costs. "The concept of the structural duct incorporated into a current IP system is a major step toward implementing the first integrated and fully functional one-piece IP system in automotive applications," said Todd Rosin, GE Plastics industry manager for instrument panel systems.

The Volkswagen New Beetle is beautiful outside and in. Take the instrument panel, including the upper carrier, which houses the gauges; the lower carrier, which is below the steering column; and the top close-out panel, which is at the base of the windshield.

The one-of-a-kind foam adhesion requirements of Volkswagen demanded high material integrity across the board. So not just any plastic would do. Only NORYL resin. And for good reason.

NORYL resin from GE Plastics gave the interior panel better heat performance, which translated into better longevity, fit and finish. GE Plastics provided three custom-tailored grades of NORYL resin for Volkswagen's distinctive instrument panel.

Striking the optimal balance of performance, processability and cost, new low-gloss CYCOLOY® PC/ABS resins manufactured by GE Plastics provide 100% molded-in color, while UV-stable materials offer the low gloss and reduced glare characteristics so important for today's instrument panel (IP) applications.

Today, many molders are facing market trends that demand them to lower part costs, consider recyclability in part design and reduce part weight. At the same time, they must also improve the soft look and feel of IP trim, work in tandem with Design For Assembly (DFA) driven productivity strategies and increase product quality to reduce buzz, squeak and rattle.

GE Plastics' material solutions to these challenges are the new low-gloss CYCOLOY resins targeted at instrument panel applications. The resins help reduce part costs with no-paint, low-gloss, molded-in color surfaces. High-quality aesthetics and UV stable parts provide consistent build quality.

In some applications, low-gloss CYCOLOY resin savings can run upwards of 30% per part. CYCOLOY LG9000 resin is targeted at IP trim applications such as speaker covers, de-frosters and grilles. Its low temperature ductility is in the 0°C to -30°C range. Applications requiring high heat deflection temperatures (HDT) in the 110° C to 130°C range can be handled by LG9000 or LG8002 grade resins. These grades are also suggested for moderate UV resistance and medium-impact applications.

Used as a solo resin, CYCOLOY LG8002 resin is suitable for IP trim applications requiring low temperature ductility to meet the Federal Motor Vehicle Safety Standards (FMVSS) 201 and 208 specifications.