Motor cover M254

VEHICLE MANUFACTURER: MERCEDES-BENZ AG
RAW MATERIAL MANUFACTURER: AKRO-PLASTIC GmbH
PARTS MANUFACTURER: WOCO Industrietechnik GmbH

For the M254 Classic / EVO, OM656 MOPF and M177 EVO platforms, the task is to develop a high-temperature-resistant, low-distortion component with an attractive design surface. The component must permanently withstand temperatures of up to 220°C and must have a distortion of less than 6 mm.

The solution involves the use of TSG (thermoplastic foam molding) in combination with precision opening and our Wocomid material. The previous version was based on PPA GF 35, but the new formulation, which is based on a 66/6 base with excellent stabilization, has resulted in significant cost savings. In addition, the mold temperature has been drastically reduced from 140°C to 80°C, resulting in a further cost advantage.

The process involves the use of MuCell technology with nitrogen. An opening stroke of 1 mm is used, which results in a reduction in clamping force. This makes it possible to pack the components directly without a cooling gauge. This method reduces the process time by 15% and also eliminates the 10 minutes that would otherwise be required for the cooling gauge.

The developed component achieves a weight saving of approx. 5% compared to a compact component with a wall thickness of 2.5 millimeters, and a 40% weight reduction compared to a comparable component with a wall thickness of 3.5 millimeters, while maintaining similar rigidity.

The component is produced at two locations: in Germany (Kronach) and in China (Wuxi).

With this new solution, significant cost savings and efficiency gains can be realized while fully meeting the requirements for temperature resistance, warpage and design surface. The innovative processes and materials not only enable improved product quality, but also more economical production.