Lightweight Mazda bumpers

February 9th, 2012 - Joe Duarte

Bumper design has a major impact on fuel economy and driving performance.

2013-Mazda-CX5-bumperTwo stage design aids manufacture

Mazda is developing new composite bumpers for its upcoming CX-5 sport utility vehicle, to improve their performance in damaging situations while also reducing vehicle weight, as well as saving energy during the manufacturing process.

More from the 2012 Chicago Auto Show

Developed jointly with Japan Polypropylene Corporation, the resin material allows for thinner parts than current composite panels, resulting in a significant reduction in the resin required for their manufacture. When the material is used for both front and rear bumpers, it contributes to weight reduction of approximately 20%.

In the production process, the reduced thickness allows for a shorter cooling period for moulding (30 seconds, compared to the traditional 60), leading to major reductions in the amount of energy consumed in the production process.

Bumper design has a major impact on fuel economy and driving performance, but they require both rigidity to absorb impact, and moulding and painting properties suitable for longevity.

The new material is a blend of two components found in polypropylene and rubber (the constituents of resin), that have different properties. They’re distributed 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 surface has excellent paint film adhesion and the inner section retains high rigidity and impact absorption.

The first application will be on the CX-5 compact utility due in spring 2012, and Mazda is claiming the lightest bumpers in the class. The process will also be used on other upcoming new models.

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