GE Helps BMW’s 3 Series Set a New Benchmark for Driving Performance

BERGEN OP ZOOM, THE NETHERLANDS— November 9, 2006 — GE today announced that its extensive portfolio of materials helped BMW meet stringent requirements for more than a dozen components in its 2006 BMW 3 Series mid-size cars. Specifically, the automaker wanted to find new ways to drive design innovation and improve fuel economy while meeting new standards of performance and durability. By using GE Plastics’ Noryl*, Lexan*, and Cycolac* resins and the company’s Visualfx* special effects resins, as well as materials from other GE businesses, BMW was able to redesign parts from the instrument panel (IP) to the headlamps to achieve such benefits as lighter weight, extreme weatherability, lower emissions, and special color effects.

Lightening Up the IP Carrier by 15 Percent

BMW chose a proprietary molding process called SGI (SpritzgussIntegral) to reduce the weight of IP carriers in the 3 Series models. To obtain the weight-reduction benefits of SGI while ensuring high dimensional stability, the manufacturer needed a resin that would be fully compatible with the SGI process, possess excellent flow characteristics, and provide high stiffness and low warpage so that instrumentation would fit precisely into the IP. For environmental compliance, the company sought to reduce volatile organic compounds (VOCs) given off by plastic components and also minimize odor within its vehicles for aesthetic reasons.

GE proposed Noryl Classico PX2390 10-percent glass fiber-reinforced resin because of its optimal compatibility with the SGI blowing agent and its high degree of rigidity. The Noryl resin grade was further modified to improve emissions performance and minimize odor. This GE resin enabled BMW to reduce the weight of the 3 Series IP carrier by up to 15 percent, and improve vehicle handling and stability. VOC reduction inside the vehicle was also a key benefit, allowing the car maker to cut emissions compared to competitive materials such as styrene maleic anhydride (SMA), polycarbonate/acrylonitrile-butadiene-styrene (PC/ABS), or long glass fiber-reinforced polypropylene (PP LGF).

Breadth and Depth of Materials Solutions

Other GE products include:

- GE Plastics: Lexan resin and Visualfx special effects resin were selected for headlamps and interior indicator lens; Cycolac resin for the center panel console; and Noryl resin for air nozzles.

- GE Advanced Materials, Silicones: Thermally conductive adhesives were selected for the water pump, braking unit, engine control unit, and headlamp controller. Silicone gels were used in the engine control unit, air flow sensor, and in some cases for the bumper.

- GE Lighting: Glass Halogen and Quartzline* Fused-Quartz Sealed Beam Lamps were used for higher light output vs. standard incandescent sealed beam lamps.

“Automotive redesign often requires a multi-pronged approach, and that’s where GE excels by providing a wide choice of solutions – all from one supplier,” said Paola Babka, Automotive Director for GE Plastics’ Automotive business. “Working with one vendor can speed up the design process, reduce management, and ensure a closer working relationship for optimal results. We’re proud that GE’s broad and deep solutions offering contributed so many different solutions to the new 3 Series, helping BMW achieve its goals of improved aesthetics, performance, and environmental responsibility.”

Reader enquiries

GE Plastics, Automotive

Plasticslaan 1
4600 AC Bergen op Zoom

+31 164 29 31 48

anne.clement@​ge.com