By Allison Preston
Troy, Michigan — November 3, 2017 — Magna has announced the creation of a new way of joining thermoplastic materials, which it claims will help automakers cut weight and costs, called torsional welding.
The torsional welding process, developed by Magna for automotive applications at its exteriors plant in Liberec, Czech Republic, is a new way to join plastics. It features a high-speed twisting motion that creates enough friction-based heat to join a plastic bracket to a thermoplastic fascia.
Magna claims the new technology achieves an approximate 10 percent weight reduction because it allows thinner materials to be joined, which in turn reduces material costs.
Torsional welding is currently used to make the front fascia of the 2017 Skoda Octavia, and it has potential for other applications where materials of similar composition need to be joined.
The company claims there may also be use for torsional welding with the increase of advanced driver assistance systems and the development of self-driving cars. It said the trend will be for automotive fascias to become heavier with the increase in autonomous features, due to the addition of sensors.
With torsional welding, says Magna, it’s now possible to reduce weight on the outer skin and brackets so more sensors can be added without impacting the overall weight of the vehicle.
When asked how torsional welding might impact the collision repair sector, a Magna spokesperson said: “There should be no impact to a collision shop. The replacement fascia will have the welded bracket as part of the assembly.”
The Society of Plastics Engineers Detroit Chapter recognized Magna’s torsional welding process with an innovation award at its recent TPO conference in Troy, Michigan.
“We seek every opportunity, from design and materials to enabling technologies, to help customers meet their lightweighting goals,” said Magna Exteriors President Grahame Burrow. “We appreciate this recognition from SPE and look forward to expanding the use of this innovative process.”
More information about Magna and torsional welding can be found on the company’s website at magna.com.
