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		Engineering the Instrument Panel Graphic courtesy of ASM The design challenges facing the interior auto designer are multifaceted. Constantly looking for ways to reduce manufacturing cost, complexity, and component weight, auto manufacturers expect improvements in dashboard manufacture. This 'exploded' diagram illustrates how different plastics are fabricated in various forms to accomplish the overall goals of light weight, strength, and reduced cost. When considering a change in material composition, the engineer has to carefully weigh the benefit gained with possible disadvantages. For instance, changing a part from metal to a thermoplastic may make it lighter, but will it be as strong? Changing from one plastic to another may reduce cost, but will the part meet safety laws? Changes in material composition often need to be employed along with new construction techniques if the change is to be effective. Photo courtesy of ASM This picture is of a glove box door for a Chrysler minivan. The component was molded from one piece using an ABS resin and features a honeycomb construction (note the checkerboard pattern). These ribs molded into the panel and back wall of the box absorb energy and help the dash meet occupant-safety requirements. The unique construction also reduce the weight by 50% compared to conventional designs, and save both piece and retooling costs for the manufacturer. Site related questions or comments? Contact crc@tms.org