Thermoformed bumper fascia looks like a cost-saver. (Keeping up with Thermoforming).

For the first time, a thermoformed bumper fascia is being considered for use on a short-run production vehicle in the U.S. The fascia system, developed by Guardian Automotive, Evansville, Ind., uses new TPO compounds and weatherable "dry paint films" to provide the Class A surface without costly painting.

"We have quoted jobs for 2005 model-year programs with lower-volume production runs," says Joe Randazzo, Guardian's director of materials and research. He says sizeable cost benefits can be won by shifting from an injection molded fascia to a thermoformed version in specialty vehicles sold in volumes of 10,000 to 20,000 units.

Most TPO fascias are currently injection molded on large presses, which calls for high initial investment. A majority of molded TPO fascias are also painted, although a growing number use "dry paint films" (a thin sheet of compatible plastic with a painted surface) to cut costs. Randazzo claims much-reduced tooling costs, faster tool deliveries, and lower machine investment for thermoformed fascias. Until now, thermoformed TPO has been limited to after-market exterior and fascia parts.

In its developmental effort, Guardian used rotary thermoforming equipment and new-generation extrudable TPOs supplied by Solvay Engineered Polymers of Auburn Hills, Mich., and Equistar Chemicals LP in Houston. Depending on the bumper design, a clear, high-gloss PVF film supplied by DuPont Fluoropolymers, Wilmington, Del., or a colored PVDF paint film from Avery Dennison's Performance Films Div. ,Schererville, Ind., is laminated to the TPO sheet prior to forming.

Randazzo says, "The bumper fascia is the largest and most demanding exterior trim application, and success for thermoforming in terms of appearance, performance, and dimension would help to dispel negative assumptions and pave the way for commercialization in other exterior trim." Avery Dennison [phone], www.pfd.averydennison.com; DuPont [phone], www.dupont.com; Equistar [phone], www.equistarchem.com; Solvay [phone].