Mazda Develops Lightweight Resin Material for Car Body

Mazda Motor Co., Ltd. has developed a resin material for automotive parts that can realize lightweighting of the vehicle body. While maintaining the same strength as conventional materials, thinner parts can be manufactured and material usage fees can be reduced. The lightest grade bumper using this resin material will be equipped in front of and behind the new multifunctional sports car (SUV) "CX-5" that will be sold this spring, and will be subsequently installed on the new model.

This material was jointly developed by Mazda and Japan Polypropylene Co., Ltd., which is engaged in the production and sales of polypropylene resin products. By using it on a bumper, it can reduce the weight by about 20%. The bumper is installed at the front and rear ends of the vehicle, so its weight will have a great influence on the fuel efficiency and driving performance of the vehicle. This resin also needs to have a rigidity that can cushion collisions, ensure the moldability of a flexible design, and sprayability.

In the manufacturing process, by reducing the thickness of the components, the cooling time during molding can be shortened, and the computer design and analysis technology can be used to optimize the fluidity of the resin material. The bumper molding time is approximately 60 seconds. Shortened to 30 seconds, only half the original. Through these initiatives, the energy consumption needed to manufacture resin materials can be greatly reduced.

The lightweight bumper is a mixture of polypropylene and rubber with different characteristics in the mixed resin material, and then forms a two-layer structure according to the function required on the surface and interior of the bumper substrate. Even if the thickness is thin, the surface achieves coating adhesion and the interior achieves excellent rigidity and impact cushioning. Mazda will continue to focus on lightweighting in order to improve the basic performance of the car.