The prominent position of the FEC as the load-bearing structure of the vehicle front poses a particular challenge in terms of quality and dimensional accuracy. Likewise, its behavior and performance in the event of a crash must be absolutely guaranteed.
Carriers are also at the forefront of structural lightweighting: the technology allows us to design this important vehicle component from scratch.
Until now, Front End Carriers have been made up of several components. The new generation is made from just one piece - thanks to lightweight structural design. Deformations and manufacturing tolerances are therefore hardly a factor. In addition, the components are manufactured to fit precisely and thus achieve a particularly high degree of tightness. This is of particular interest in terms of air resistance and cooling.
This is made possible by the plastic material base. An additional advantage is that with this one-piece solution we achieve a much more precise geometry. Corrosion also hardly plays a role thanks to our high-performance plastic.
Everything already inside
Of course, all the advantages of Structural Lightweight technology, such as lower weight and cost-effective production, also apply to Front End Carriers. This component in particular also benefits from functional integration and pre-assembly of other components. This applies, for example, to lights, sensors, active grille shutters (AGS) and more.
Some highlights of our Front End Carrier
Lightweight, application-specific material with proven mechanical performance and material card for crash simulation.
"One-shot design" enables significant cost and weight savings as well as a reduction in installation space
Lower overall height
Optimized use of installation space thanks to maximum design freedom
Extended range due to low weight: up to 30% lighter per square meter compared to steel and aluminum
Robust design, excellent long-term stability and corrosion resistance
Excellent sealing performance thanks to one-shot and one-piece design. Continuous sealing surface without interruptions.
Functional integration or assembly of sealing and purchased parts as a cost-effective solution.
Advantages and competencies of Röchling Automotive
Röchling supplies complete systems
Design, development, and production from a single source, tailored to our customers' requirements
Structural simulation available in-house
Simulation capacities for processing are under development at our company
Validation from material to product level
Over 20 years in the development and series production of high-performance plastics
Many years of experience in end-of-line testing (leak and quality control)
Global presence for prototyping and series production
Wall thickness between 1.8 and > 5 millimeters matched to the application
Optimized packing dimensions
Best sealing properties
Hybrid design with local reinforcement by metal or continuous fibers possible
Active Grille Shutter (AGS)
Additional fire resistant materials
Management of fluid lines, cables, etc.
Injection molding PP-GF & PA6-GF
Compression molding PP-GF & PA6-GF
Tape integration for local reinforcements
Various press sizes and manufacturing methods available
Stack mold concepts for injection molding
Multi-cavity mold for D-LFT and SMC compression molds, depending on part footprint
In-house developed materials for compounding thermoplastic injection molding and compression molding