Slush molding, PU spray gain in IP applications. (Market Focus).

PVC/ABS thermoformed skins for instrument panels (IP) have lost market share to slush molding and polyurethane spray in both North America and Europe. Market demands for accurate, uniform grain retention and the emergence of instrument panels with sharper angles have favored these alternatives to vacuum forming despite their higher cost, says a new report from Robert Eller Associates (REA). The Akron, OH-based consulting firm indicated that "the growing popularity of the invisible airbag door and the requirement for deployment at low temperatures (-30 -40[degrees]C) have favored alternatives to PVC but recent mechanical developments at Audi facilitating low temperature airbag deployment and favorable economics will support the continued use of slush-molded PVC."

PVC/ABS sheet's market share in North American instrument panel skins dropped from 56% in 1997 to 35% in 2002. Favorable pricing vs. PU and TPO alternatives will reverse the decline in PVC slush skin share and result in share gain through 2007.

PU spray skins from Recticel will enjoy big gains in both European and N. American high-end vehicles in the next five years due to the excellent grain reproduction and the ability to accommodate sharp angles. The report adds "the success of PU spray in instrument panels has encouraged the use of PU spray in door trim panel production and we are looking at the savings potential from semi-direct door trim fabrication processes."

The study, "Automotive interior soft trim: Skins, foams, coated fabrics, textiles and acoustic barriers," is REA's second study analyzing the technology, economics and markets for auto interior soft trim.

Instrument panel surface shares (NAFTA)1997

 3%  UEV Vac form
50%  PVC ABS Vac form
30%  Hard (no skin)
17%  PVC slush

Instrument panel surface shares (NAFTA)2002

34%  Hard (no skin)
15%  PVC slush
 7%  TPO Vac forum
 2%  TPU slush
 2%  PU spray
 4%  Other