Combining Materials and Functions for Low Cost Manufacturing of Headliners

Headliners are large parts that must be lightweight, sound absorbent and sturdy enough to carry a complement of other interior components as well. And as the dashboard becomes loaded with more and more technologies, there is a drive to spread some of that complexity over the rest of the interior of the car. Automotive headliners offer an opportunity for slashing vehicle production costs by integrating components and functions in a one-step operation. The headliner is the ideal candidate not only to accept sun visors, lighting systems and hand grips, but also garage door openers, cellular telephones and audio speakers.

This paper will discuss the use of low pressure injection molding as a way to reduce headliner production costs while expanding functionality. It will also examine the equipment requirements and the implications of this process for designers and manufacturers of vehicle headliners.