Nylon grade lowers cost of manifold

By using Bayer Plastics Durethan polyamide 6, Mann + Hummel Automotive was able to make a double switch in the design of their air intake manifolds used in General Motors’ 4-cylinder, 2.2-litre Ecotec engine.

By replacing lost core molding with multishell technology using Bayer engineering resin, the company was able to improve noise quality, and lower costs. “The properties of the Durethan resin and how it molds are the keys to the project,” said Rick Weckerle, manager and project engineer at Mann + Hummel.

The air intake manifolds are formed from Durethan BKV-30H2.0 1510 black resin. This 30-percent-glass-filled, heat-stabilized nylon 6 resin offers a desirable combination of high strength and toughness, as well as chemical and abrasion resistance.

Mann + Hummel injection molds three individual shells of the manifold — upper, inner, lower — using Durethan resin. When molding is complete, the shells are joined together through vibration welding to form the complete manifold.

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