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10/02/2012
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Mazda Motor Corporation has created a new resin material for vehicle parts that maintains the same rigidity as parts made with conventional materials, while achieving weight reductions.
 Using this material, developed jointly with Japan Polypropylene Corporation, the parts manufactured can be thinner than those using conventional resin, resulting in a significant reduction in the resin required for each component.
When the new material is used for both the front and rear bumpers of a vehicle, it contributes to a weight reduction of approximately 20 percent. In the bumper production process, this reduced thickness allows for a shorter cooling period for moulding, and by using computer-aided engineering (CAE) technology, the fluidity of the resin material has also been optimised.
As a result, bumper moulding time, previously 60 seconds, has been halved to 30 seconds, leading to major reductions in the amount of energy consumed in the production process.
Mazda plans to adopt the world's lightest bumpers in its vehicles with engine displacements between 1500 to 2000cc. Mazda will use this new resin material in the all-new Mazda CX-5 compact crossover SUV which goes on sale this spring, as well as many future models.
Bumper weight has a major impact on fuel economy and driving performance. However, bumpers are also multi-functional - requiring both the rigidity to absorb impact, and the moulding and painting properties suitable for excellent exterior design.
Mazda blended two components found in polypropylene and rubber, the constituents of resin, that have different properties, and succeeded in distributing them in a double-layer structure in line with the required function for the surface and the inside of the base bumper material. As a result of this achievement, the exterior surface has excellent paint film adhesion and the inner section retains high rigidity and impact absorption, with reduced thickness.
Moving forward, Mazda remains committed to reducing vehicle weight and improving dynamic performance in order to provide all its customers with a high level of driving pleasure and outstanding environmental and safety performance that is typical of the Japanese brand.
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Author
John Challen
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