Alexei Volkov
Plastic is one of the most frequently used materials in vehicle manufacturing. Plastics have been playing an increasingly vital role in the performance and design of dashboards. Dashboards are typically made from Acrylonitrile Butadiene Styrene (ABS), a polycarbonate alloy, polycarbonate, polyester, or polypropylene. Polypropylene is the most frequently used plastic in automotive manufacturing due to its ability to be formed into almost any shape, as well as its excellent chemical and heat resistance. Polycarbonate is also commonly used in dashboards for its strength and safety.
| Characteristics | Values |
|---|---|
| Plastic Type | Polyvinyl Chloride (PVC), Polypropylene (PP), Acrylonitrile Butadiene Styrene (ABS), Polycarbonate (PC) |
| Plastic Properties | Flame retardant, formability, sleek finish, impact resistance, weather resistance, lightweight, thermal stability, electrical insulation, flexibility, rigidity |
| Metal Attachments | Aluminum, metal bolts, nuts, screws, springs |
| Manufacturing Process | Injection moulding, rotational moulding, vacuum forming, thermoforming, injection moulding |
| Application | Dashboards, automotive body parts, steering wheel covers, bumpers, headlight lenses/covers |
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What You'll Learn
- Polyvinyl Chloride (PVC) is a common plastic used in dashboards
- ABS plastic is used for dashboards and automotive body parts
- Polypropylene (PP) is being developed as a basic material for dashboards
- Polycarbonate (PC) is blended with ABS for dashboards
- Metal parts are required to reinforce plastic dashboards
Polyvinyl Chloride (PVC) is a common plastic used in dashboards
PVC is often used in dashboards because it can be formed into either flexible or rigid components, providing a sleek finish. It is also a flame retardant, which is an important safety feature for car interiors. During the manufacturing process, plasticizers and phthalates can be added to soften the PVC.
The use of PVC in dashboards is part of a broader shift in automotive manufacturing from metal and steel to moulded plastic components. Plastic is much less expensive to source and manufacture than metal, and it is significantly lighter, reducing fuel consumption and greenhouse gas emissions.
While PVC is commonly used for dashboards, other plastics such as polypropylene (PP) and polyurethane (PUR) are also being developed for this purpose. Additionally, dashboards may be made from Acrylonitrile Butadiene Styrene (ABS) plastic, either on its own or blended with polycarbonate. ABS is known for its toughness, rigidity, and impact resistance, making it a durable option for car interiors.
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ABS plastic is used for dashboards and automotive body parts
Plastic is now one of the most frequently used materials in vehicle manufacturing. Over the past few decades, automotive manufacturing has seen a shift from metal and steel to moulded plastic components, parts, and products. This is due to plastic being much less expensive to source and manufacture, and significantly lighter, which reduces fuel consumption and greenhouse gas emissions.
ABS plastic, or Acrylonitrile Butadiene Styrene, is one of the most common plastics used in automotive manufacturing. It is very hard, tough, and rigid, making it incredibly resistant to impact. It is also heat and water-resistant, making it highly durable. ABS plastic is well-suited to heavy-duty applications and is often used for automotive body parts. ABS plastic sheets offer excellent design flexibility, enabling the creation of complex and intricate automotive parts.
ABS plastic is commonly used for dashboards and dashboard components, including instrument panels, centre consoles, and interior trim. It is ideal for these applications because it is lightweight, impact-resistant, and has good heat resistance. It also has good surface finish characteristics, making it perfect for parts that require a high-quality finish. ABS dashboards offer excellent durability and impact resistance, making them ideal for the automotive interior. The material's high tensile strength ensures that dashboards can withstand daily wear and tear, including exposure to sunlight and temperature fluctuations.
ABS plastic is also used for the production of bumpers, fenders, exterior trim, and wheel covers. It is ideal for these applications because it is lightweight, durable, and impact-resistant. ABS plastic can also be used for body panels, such as door panels and side panels, through the process of thermoforming. This involves heating a sheet of ABS plastic until it becomes pliable, then stretching it over a mould and cooling it to form the desired shape.
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Polypropylene (PP) is being developed as a basic material for dashboards
Polypropylene (PP) is a highly versatile plastic that is widely used in various industries, including automotive, packaging, electrical, and consumer goods. In the automotive sector, PP is commonly used for manufacturing automotive interiors, such as dashboards, due to its many advantageous properties.
PP is a lightweight material, making it ideal for industries where weight reduction is a priority, such as automotive and packaging. Its low weight helps reduce the overall weight of a vehicle, leading to improved fuel efficiency and reduced fuel consumption and emissions. Additionally, PP's low density compared to other plastics contributes to cost savings.
Polypropylene exhibits excellent impact resistance, making it suitable for automotive applications where durability is essential. It also offers good chemical and heat resistance, further enhancing its suitability for automotive components. PP's high tensile strength, with the ability to withstand 4800 psi, contributes to its overall durability.
In terms of processability, PP can be easily formed into almost any shape using various thermoplastic-processing methods, including extrusion blow moulding, injection moulding, and general-purpose extrusion. This versatility in processing enables its use in creating diverse automotive parts, such as dashboards, bumpers, cladding, and exterior trim.
The development of PP as a basic material for dashboards and other automotive components is driven by its favourable combination of lightweight, durability, impact resistance, and ease of moulding. These properties make PP a cost-effective and versatile alternative to other plastics, contributing to its increasing adoption in the automotive industry.
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Polycarbonate (PC) is blended with ABS for dashboards
Polycarbonate (PC) is a polymer that is highly impact-resistant and stands up to UV rays, water, heat, and cold, making it weather-resistant. It is also transparent and lightweight. Acrylonitrile Butadiene Styrene (ABS) is a very hard, tough, and rigid plastic with similar weather-resistant properties. ABS is also easy to process. When blended with PC, the resulting PC/ABS material combines the best of both worlds. It is highly impact-resistant, heat-resistant, and weather-resistant. It is also easy to process, rigid, and tough, but still pliable enough to form features that are not possible with metal.
PC/ABS is used in a wide range of applications, including automotive interior parts, consumer electronics, electrical enclosures, connectors, housings, and medical devices. It is well-suited for applications where durability, aesthetic appeal, and biocompatibility are important. PC/ABS is also used in aerospace applications for interior components, cabin trim, and instrument panels due to its lightweight nature and aesthetic appeal. In addition, this blend can meet stringent regulations for fire behavior, electrical safety, and resistance to chemicals, hydrolysis, and heat when combined with fire retardant additives.
PC/ABS is commonly used in automotive interior components such as dashboards, door panels, and trim due to its impact resistance and aesthetic properties. PC/ABS blends offer a sleek finish, similar to PVC, and are well-suited for heavy-duty applications. They are also used in steering wheel covers. Dashboards made from PC/ABS can protect the vehicle's mechanics against moisture, impact, abrasion, excessive heat, and harmful UV rays.
Polypropylene is another plastic commonly used in automotive manufacturing due to its versatility, heat resistance, and impact resistance. It is often used in car bumpers, gas cans, and carpet fibers. However, PC/ABS blends provide enhanced impact resistance compared to polypropylene, making it suitable for products subjected to high stress or potential impact. Overall, the blend of Polycarbonate (PC) and ABS combines the durability of polycarbonate with the ease of processing of ABS, making it ideal for various applications, including automotive dashboards.
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Metal parts are required to reinforce plastic dashboards
Plastic is now one of the most frequently used materials in vehicle manufacturing, with polypropylene being the most commonly used plastic in automotive manufacturing. Polypropylene is a thermoplastic polymer that can be formed into almost any shape and is highly resistant to heat, chemicals, and impact. Polyvinyl chloride (PVC) is also commonly used in cars due to its formability, sleek finish, and flame retardance.
While plastic is prevalent in modern vehicles, metal parts are still required to reinforce plastic dashboards. During the development of plastic dashboards, test units are used to determine where the instrument panel needs to be reinforced with metal. Metal bolts, nuts, screws, and springs are used to hold the panel and its instruments in place, especially for safety-critical components such as air vents and airbag units. These metal parts, known as D-parts, must meet stringent safety requirements. For example, screws must always be tightened with the same amount of torque, and compliance with these requirements must be carefully documented.
The use of metal reinforcements in plastic dashboards is primarily driven by safety considerations. Lightweight plastic instrument panels, while contributing to weight reduction and fuel efficiency, lack the structural integrity of metal. Aluminum, being a lightweight metal, is often chosen for these reinforcements to meet low-weight requirements. Additionally, the integration of metal parts during the manufacturing process ensures the stability and longevity of the dashboard.
While plastic has revolutionized automotive design and reduced manufacturing costs, metal still plays a crucial role in enhancing the safety, durability, and stability of vehicle components, particularly in plastic dashboards. The combination of plastic and metal in modern vehicles showcases the ongoing innovation and collaboration between these materials to achieve improved performance, efficiency, and safety.
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Frequently asked questions
Dashboards are typically made from Acrylonitrile Butadiene Styrene (ABS), or an ABS polycarbonate blend. Other plastics used include polycarbonate alloys, polycarbonates, polyester, and polypropylene.
Acrylonitrile Butadiene Styrene (ABS) is a common plastic used in injection moulding. It is a strong, impact-resistant plastic that can be easily machined and fabricated.
Polycarbonate is a clear, impact-resistant plastic that is 250 times stronger than glass. It is often used as a safety glazing material.
Metal attachments and reinforcements are used in dashboards for safety reasons. Aluminium is often used to meet low-weight requirements.
Any automotive interior cleaner should work on a plastic dashboard. Some prefer Meguiar's Quick Interior Detailer as it doesn't leave surfaces shiny.
