Development Of Semi-Structural And Multifunctional Body Parts In Plastics Within The PEUGEOT SA Group: Example Of The PEUGEOT 405 Front End Frame

Over the last ten years the PEUGEOT SA group has developped several multifunctional parts in plastics: the front end frame in 42 % glass SMC of the new PEUGEOT 405 shows a high degree of multifunctionnality: more than 15 components are fitted on this panel, among them the bumper, the headlamps, the front grill, the radiator etc… The part has a structural function as it closes the front end of the car body; it works as a fixture for the fitting of the equipments and thus improves the overall aspect quality of the vehicule front end. This paper describes the prototype phase (material, simulation tests), the most important production steps at the custom moulder plant (finishing operations by laser, automatic inserts fitting) and finally the ultimate operations in the production plant of Automobiles PEUGEOT: fitting of accessories (mainly by robots) and assembling on car body.