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As petroleum prices experience record volatility, automotive OEMs are seeking advanced materials that permit the development of more light weight, fuel efficient vehicles. Thermoplastics are a natural solution since they provide the combination of structural properties with lower material density, along with ease of forming geometrically complicated parts with rapid cycles and with minimal finishing operations. However, new automotive applications are becoming increasingly demanding with regard to chemical exposure, environmental exposure, thermal environment, and load bearing requirements. Addressing these challenges requires a thorough understanding of the application in order to identify appropriate thermoplastic resins and to develop novel resin technologies to extend the performance of structural engineering thermoplastics.

The use of injection molded long glass fiber composites to replace metal in automotive components continues to find success. This paper will discuss the use of these composites to replace steel in running boards, a very demanding application. The success of an injection molded-in-color composite running board on a 2004 mid size SUV has opened the door to realize the benefits of composites in these large exterior parts. These benefits include significant weight reduction, corrosion resistance, scratch and mar resistance, design flexibility, and cost out opportunities. 40% long glass fiber polypropylene was formulated to meet the rigorous structural and aesthetic requirements demanded by global OEM manufacturers for these large structural parts.