FORD FIESTA BODYKIT FIRST TO MARKET USING RENPIP NEW RENPIP MATERIALS DELIVER 20-FOLD INCREASE IN PART PRODUCTION RATES
30 June 2004 - Huntsman Advanced Materials

Prior to the introduction of the RenPIP materials, SW Autodesign had five skilled
laminators; each producing five parts per day, using five moulds each.

Using RenPIP, the daily production rates per man, per tool have increased 20-fold over the previous GRP system, with two operators working two machines, using three moulds each, producing a total of 128 parts per day.

“The use of the RenShape Solutions RenPIP rapid setting polyurethanes has enabled us to produce OEM quality parts at a fraction of the cost and the development time required to produce traditional high-pressure PUR parts,” said Gary Lendon, Group Operations & Marketing Director, at SW Autodesign.

“As a result of using these rapid production processes our Ford Fiesta body styling kit was the first available in the UK and Europe, helping us to establish a major foothold with Ford’s national dealerships.”

Ford Fiesta Programme
SW Autodesign wanted to use RenPIP rapid setting polyurethanes for the Ford Fiesta programme having used them previously for some specialist short production run parts.

However, due to the enormous engineering stresses put on these parts the RenPIP
materials would have to meet MG-Rover’s RES Engineering standards for exterior PUR parts and those laid down by the major automotive manufacturers and body shops for finished painted parts, before they could be used.

The vulnerable position of the installed parts, such as rear spoilers and side skirts,
means they are subjected to extreme impact and climatic effects. For example ambient temperatures can range from -30°C up to +110°C. The parts also had to be able to withstand low speed (5mph) impacts as well as collapsing safely in a high-speed impact (120mph).

SW Autodesign produced some test parts using different blends of RenPIP polyurethanes to maximise flexibility, strength, and high impact resistance. They also produced parts in RenPIP 5215 for its high temperature resistance and in RenPIP 5221 for very high impact resistance, suitable for crash testing and able to simulate PE.

MG-Rover then tested these parts to their RES standards including impact tests down to a temperature of -30°C and thermal tested at up to 110°C.The finished, painted parts were tested by BASFGlasurit on a range of surface finish quality criteria to BS 3900 Part 1, BSAU 148 and BS 1006. They were also subjected to 500 hour endurance tests against humidity and blistering.

All the RenPIP parts successfully passed the BASF tests and MG-Rover’s RES standards. SW Autodesign subsequently used the blended RenPIP 5217/5212 for the Ford Fiesta body kit, comprising a front apron (spoiler/splitter), side skirts and a rear apron. They also used RenGel polyurethane gel coats and materials on the production of cast tools.

“The flexibility of this rapid part production system compared to GRP makes the parts easier to install, so reducing vehicle fitment times and improving conversion productivity rates,” concluded Gary Lendon.

SW Autodesign has now installed a third dispensing machine to run a specific long-term MG-Rover programme. This new machine will run three multi-cavity (both dual and quad) tools, which will double/quadruple the tool output respectively. Production is scheduled to commence in Spring 2004.

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