An assembly of mating subassemblies having dimensional control features for a motor vehicle is provided. The assembly includes a composite molded first subassembly having a first set of molded-in dimensional control features. The assembly also includes an injection molded second subassembly having a second set of molded-in dimensional control features. The first and second sets of dimensional control features are integrally formed on their respective subassemblies to permit contact between the first and second sets of control features when the subassemblies are assembled together.

An assembly for a motor vehicle is provided. The assembly includes a plastic molded part having an exterior surface and a low load region adapted to accommodate a low load. The low load region is formed using thin wall injection molding (TWIM) technology. The assembly also includes at least one load bearing spacer adapted to accommodate a high load that is greater than the low load. The spacer is configured to extend along a load path to accommodate and forward a load on a top portion of the part to a bottom portion of the part.

An add-on part (10) for connecting to a component (30). The add-on part (10) has a longitudinal axis (A) and a welding section (11) to be welded to the component (30) by torsional ultrasonic welding. The welding section (11) has a contact surface (12) for contact with a torsion sonotrode (70) and a welding surface (13) for connecting to the component (30). The welding section (11) is delimited, at least in some sections, by an inner vibration-decoupling zone (14). The inner vibration-decoupling zone (14) extends, at least in some sections, at an inclination to or parallel to the longitudinal axis (A). The method comprises a) bringing the welding surface (13) in contact with a welding region (31), b) applying a force to the contact surface (12) such that the welding surface (13) is pressed against the welding region (31), and c) introducing a torsional ultrasonic vibration into the welding section.

A liftgate assembly having finished show surfaces, and process of manufacturing same. The liftgate assembly includes local reinforcements that are overmolded to first reinforcements, and the first reinforcements are infrared welding to a first panel. Second and third reinforcements are also infrared welded to the first panel. To infrared weld the respective reinforcements to the first panel in predetermined locations with respect to the first panel, nesting structures are provided to hold the respective reinforcements and first panel. At least one infrared heating fixture heats various predetermined surfaces on the reinforcements and first panel, and the parts are then pressed together for joining the predetermined surfaces of the respective parts together. The process is repeated, if needed, until all of the reinforcements are infrared welded to the first panel. Outer panels are bonded to the second and third reinforcements.

A resin structure includes a first structural portion and a second structural portion. The first structural portion includes a characteristic design surface and structures an end portion at a side of the resin structure at which the characteristic design surface is disposed. An orientation direction of fibers in a first pattern portion of the first structural portion differs from an orientation direction of fibers in a second pattern portion. The second structural portion includes a region disposed at the opposite side of the first structural portion to the side at which the characteristic design surface is disposed. Fibers contained in the second structural portion differ in fiber width from the fibers contained in the first structural portion. A portion of the fibers contained in a region of the second structural portion superposed with the first structural portion are configured to be visible through the resin of the first structural portion.

Disclosed herein is a vehicle spoiler, and more particularly, a vehicle spoiler with improved adhesive strength between a fixing member and a spoiler body due to a structure of the fixing member which is provided with an adhesive surface surface-treated in an embo shape and a protrusion formed to protrude at a predetermined height in a vertical direction of the adhesive surface, and a manufacturing method thereof. The vehicle spoiler includes a spoiler body installed in a vehicle trunk in a width direction and formed in a plate shape, a fixing member which is coupled to a lower surface of the spoiler body in a vertical direction and which includes an adhesive surface having one surface undergoing surface treatment and a protrusion formed to protrude at a predetermined height in a vertical direction of the adhesive surface, and an adhesive applied to the adhesive surface of the fixing member.

An article includes a body that has a solid shell that encloses an interior region. The interior region has a solid sub-region, a lattice sub-region, and a hollow sub-region that are exclusive of each other and distributed based on load path. In an example, the article is a spoiler cap, such as for the spoiler on a vehicle.

A method for producing a lower part of a rear spoiler of a motor vehicle includes providing at least one insert part and fibers, arranging the fibers and the at least one insert part in a mold, and incorporating a matrix into the mold. The method further includes molding the lower part of the rear spoiler in the mold, wherein the insert parts are laminated into the structure of the lower part, and milling the insert part after the molding of the lower part.

A process of making a drag-reducing aerodynamic vehicle system includes injection molding a body configured for attachment to a roof of a vehicle with a sliding core, wherein the body comprises an air inlet extending through a surface of the body, wherein the air inlet includes an air guide boss extending from an interior surface of the body, wherein the air guide boss adjusts an air stagnation point away from the windshield to reduce air pressure and drag on the vehicle; and ejecting the drag-reducing aerodynamic vehicle system from the injection mold using the sliding core.

A resin structure includes a first structural portion and a second structural portion. The first structural portion includes a characteristic design surface and structures an end portion at a side of the resin structure at which the characteristic design surface is disposed. An orientation direction of fibers in a first pattern portion of the first structural portion differs from an orientation direction of fibers in a second pattern portion. The second structural portion includes a region disposed at the opposite side of the first structural portion to the side at which the characteristic design surface is disposed. Fibers contained in the second structural portion differ in fiber width from the fibers contained in the first structural portion. A portion of the fibers contained in a region of the second structural portion superposed with the first structural portion are configured to be visible through the resin of the first structural portion.