Driven by CO2 regulations and associated weight reduction efforts, but also styling differentiation and a modular approach to increase manufacturing efficiency, car-makers are considering more and more plastic and composite technologies for closure systems. As a consequence, Plastic Omnium, the market leader has been able to double its production over the past 5 years and will deliver in 2014 more than 1 million tailgates with more than 10 new production launches since 2010. This major step forward has been achieved via the introduction of a new concept called "Higate". This technology combines a thermoset inner shell and thermoplastic outer panels which are bonded together and delivered top-coated to the car-maker. To reach higher production volumes and improve cost competitiveness, an alternative thermoplastic solution for the inner shell using over-moulded steel inserts to improve mechanical performance has been developed as an alternative option to the thermoset inner shell To achieve the expected level of performance, Plastic Omnium launched a three-year innovation program with PSA to adapt the composite thermoplastic technology to PSA specifications. Thanks to this composite thermoplastic concept, Plastic Omnium is able to deliver for the new PSA 308 models a competitive alternative to steel providing weight saving, new styling possibilities and production capacity of up to 1000 parts per day with one set of tools.
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