BASF SE and ContiTech AG’s vibration control unit have claimed a milestone, with the first use of plastic for an automotive transmission cross beam. The nylon component is standard in the new BMW 5 Series Gran Turismo 550i.
The companies claim using a BASF Ultramid resin instead of aluminum cut the weight of the part by 50 percent.
The cross beam was developed by Hannover-Germany based ContiTech Vibration Control GmbH, in cooperation with BMW and BASF. Just a few days after series production started, the beam landed a first-place Innovation Award conferred by the Federation of Reinforced Plastics (AVK).
The transmission cross beam is a structural component designed to cope with high loads. It contributes to the overall rigidity of the vehicle and must withstand the forces and torque generated by the engine-transmission unit, as well as high temperatures resulting from proximity to the exhaust system.
ContiTech produces the component from “exceptionally strong” nylon by injection moulding. With the help of BASF’s Ultrasim development instrument, it was possible to reduce the weight by 2.2 pounds compared to the same component made of metal — cited as highly significant in lightweight car construction. In addition to weight reduction, development focused on optimizing vehicle acoustics and crash safety.
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