Automotive Front End Structures Constructed by Over Molding Hydroform Metal Tubes to Engineering Thermoplastic Structures

This paper presents a new type of engineered structure that combines a pressure sequenced hydroform (PSH) tube over molded to an injection molded engineering thermoplastic (ETP) panel. A unique attachment feature is formed during the molding process. This eliminates separate mechanical fasteners that would otherwise be necessary to connect the tube to the plastic panel.

This paper takes the reader through the process that was used to bring about a Hydroform – Plastic Structure (HPS). From the initial brainstorming approaches through the validation testing, each step will show how this technology was developed. Details accompany each step to illustrate the finer points of the application development with this structure. The application under investigation is an automotive front-end module. The front-end module serves as a structural member and vehicle hardware integrator at the front of the engine compartment.