Instrument Panel for E-Mobility

Use Case

Instrument Panel for E-Mobility

Automotive, E-Mobility

### Summary of Lightweight Material for Instrument Panels (IP) & Door Panels (DP) Compared to Slush Molding The material from Tatsuta Chemical is used for **instrument panels (IP) and door panels (DP)** in automobiles, providing **lightweight, high-quality surface finishes**. Here’s how it compares to **slush molding**: #### **1. Thermoforming vs. Slush Molding** - **Thermoforming Process (Used with Tatsuta Material)**: - Uses a **pre-formed sheet** heated and vacuum-formed over a mold. - Less material wastage. - Can integrate **reinforcements** like back-foaming to add structure without extra weight. - **Consistent thickness** leading to more predictable mechanical properties. - **Slush Molding**: - Uses **PVC powder**, which is poured into a mold, heated, and then excess material is removed. - Results in **thicker** and **heavier parts** due to the nature of the material build-up. - Involves **higher material waste**. #### **2. Weight Reduction** - Tatsuta’s material is **lighter** because: - Uses **TPO-based skin** instead of **PVC** (PVC is denser). - Can be reinforced with **lightweight foams** or substrates. - Thermoformed parts **require less resin**, unlike slush-molded parts which accumulate extra material. - **Example of Weight Difference**: - **Slush-molded IP**: ~4.5–5 kg per set. - **Thermoformed IP with lightweight reinforcement**: ~3.2–3.8 kg per set. - **Savings of 20-30% in weight**, leading to better fuel efficiency. #### **3. Cost & Process Efficiency** - **Lower Material Cost**: Thermoforming allows the use of **co-extruded sheets**, reducing material consumption. - **Lower Cycle Time**: **Thermoforming process cycle time ~90-120 sec**, compared to **slush molding (~180 sec or more)**. - **No Need for Secondary Processing**: Slush molding often requires **post-processing steps like trimming and edge folding**, whereas **thermoforming integrates these into the process**. #### **4. Aesthetic & Durability Advantages** - Tatsuta’s **TPO-based sheets**: - **Better UV resistance** (less yellowing over time). - **Softer touch feel** without the weight of thick PVC layers. - **Easier to texture** compared to slush-molded PVC skins. #### **5. Market Adoption in India** - **Thermoforming + Press Lamination** is becoming popular in **premium vehicles** due to: - Weight savings leading to **higher fuel efficiency**. - **Sustainability concerns** (TPO-based vs. PVC-based skins). - Growing adoption by **OEMs like Suzuki, Tata, Hyundai**. ### **Conclusion** Thermoformed surfaces using Tatsuta’s materials offer **significant weight savings (~30%)**, faster cycle times, and **improved material efficiency** compared to slush molding. This makes them ideal for **cost-effective, high-quality automotive interior production**.