Citation:

Dhrudipsinh Dabhi, 2022. "Advanced Material Optimization for Enhanced Knit-Line Integrity in Automotive Interior Components: A Design of Experiments Approach", ESP Journal of Engineering & Technology Advancements 2(3): 116-123.

Abstract:

In August 2022, a critical issue arose with a molded plastic component in an automotive interior application due to weak knit lines. The part was prone to breakage under minimal pressure, which impeded the final form-fit-function testing required for production approval. The weak knit line was identified as a significant roadblock, affecting the entire assembly process and necessitating a quick, effective solution to move forward with production. This research documents the detailed design of experiments (DOE) performed to evaluate the feasibility of an alternative material, polypropylene, to enhance the knit-line strength. The results demonstrated improved performance with polypropylene, but final approval challenges remained due to the original material's specified low-emission requirements and customer-preferred attributes. This paper offers a valuable roadmap for similar troubleshooting efforts, highlighting how material selection, mechanical properties, and customer-specific requirements intersect in the context of automotive component manufacturing.

References:

[1] Smith, J., & Thompson, K. (2021). Polypropylene and its Applications in Automotive Interior Components. Journal of Polymer Science, 47(5), 234–245.

[2] Johnson, R., et al. (2020). Thermoplastic Olefin Elastomers in High-Performance Automotive Applications. Polymer Engineering & Science, 60(7), 890–905.

[3] Patel, M., & Huang, T. (2019). Effect of Knit-Line Formation on the Mechanical Properties of Injection Molded Parts. Journal of Injection Molding Technology, 34(2), 176–189.

[4] Lee, S., & Yamamoto, D. (2018). Material Innovations in Automotive Interior Applications: Balancing Durability and Emissions Compliance. International Journal of Automotive Engineering, 45(3), 320–338.

[5] Wilson, P., & Garcia, L. (2017). Advances in Mold Design for Enhanced Knit-Line Strength. Plastics Engineering Journal, 41(4), 212–227.

Keywords:

Knit Line, Injection Molding, Polypropylene, Thermoplastic Olefinic Elastomer, Automotive Interior Components, Material Selection.