SABIC and Dongfeng Motor Develop New Composite Plastic Hybrid Solution for Light Truck Tool Boxes

On February 15, SABIC revealed that the company has cooperated with Dongfeng Motor, a major Chinese truck manufacturer, to develop a new composite plastic hybrid solution for the production of strong and lightweight vehicle tool boxes
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The application mixes SABIC's STAMAX® long-glass polypropylene resin and a continuous glass-fiber composite laminate insert, produced using a two-shot injection molding process
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Compared with steel parts of similar design, the weight of finished parts produced by this solution is reduced by 30%, and the production efficiency of Dongfeng Motor is effectively improved
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Abdullah Al-Otaibi, General Manager, ETP and Market Solutions, SABIC, said: “This composite plastic solution is yet another success story of SABIC helping customers in the automotive industry expand design options and simplify production processes
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By combining two different materials, our The solution significantly improves product performance and processability
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At present, this composite material technology has passed production verification and has begun mass production in Dongfeng Motor.
We hope that more applications in the automotive field can benefit from it in the future, and look forward to helping Automakers seize these opportunities
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In addition to truck kits, automotive applications for STAMAX resin hybrid solutions include tailgates, seats, front-end modules, and battery housings for electric vehicles
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Using this composite plastic solution can not only help manufacturers reduce body weight, but also reduce carbon emissions, control costs by increasing production efficiency, and improve vehicle performance
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Design and performance optimization

SABIC's hybrid solutions combine STAMAX resins with thermoformed composite inserts
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The insert is made from a unidirectional glass fiber reinforced polypropylene tape produced by Jiangsu Qiyi Technology, a producer of continuous glass fiber reinforced thermoplastic composites
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Laminate inserts are preheated before being placed in the mold and are two-shot injection molded with STAMAX resin in one operation
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This insert increases stiffness and strength in critical areas of the part, enabling thin-wall geometries to reduce part weight
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Compared to the steel traditionally used in truck toolboxes, SABIC's composite plastic hybrid solutions offer a wider range of design options, enable integrated production of parts, and avoid secondary operations that can add cost and hinder mass production
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Truck toolboxes produced with plastic composite solutions are approximately 30% lighter (4 - 6 kg) while maintaining the rigidity, toughness and strength required for the application
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The density of STAMAX resin is 10-25% lower than some competing materials, thus reducing part weight
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In addition, it has the advantages of high stiffness and impact resistance, excellent structural properties, and high flow properties, making it ideal for the production of thin-walled parts
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