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Automotive fenders is one such example where specialized thermoplastic material Noryl GTX* (blend of Polyphenyleneoxide (PPO) + Polyamide (PA)) has successfully replaced metal by meeting functional requirements. The evolution of a fender design to fulfill these requirements is often obtained through a combination of unique material properties and predictive engineering backed design process that accounts for fender behavior during the various phases of its lifecycle. This paper gives an overview of the collaborative design process between Mitsubishi Motors Corporation and SABIC Innovative Plastics and the role of predictive engineering in the evolution of a thermoplastic fender design of Mitsubishi Motors Corporation's compact SUV RVR fender launched recently. While significant predictive work was done on manufacturing and use stage design aspects, the focus of this paper is the design work related to identifying support configuration during the paint bake cycle.

Multi-material solutions for the light weighting of electric and internal combustion engine (ICE) vehicles is an emerging trend to replace structural components made of steel/aluminum. Automotive chassis consists of structural members such as rails, posts and rockers, which form frames that need to meet stringent crashworthiness requirements such as frontal, side (IIHS & Pole) and rollover impacts. The high strength steel and aluminum used in these structures are often heavy and require several secondary steps to complete the frame. In the present paper, we discuss the design and optimization of multi-material hybrid rocker panel solutions to meet pole impact requirements and decrease weight with an emphasis on structural battery protection in electric vehicles. Rocker panel structures are situated at the bottom of the lateral edges of the vehicle and extend longitudinally along the length of the vehicle, between the front and rear wheels.