Regency
The Market
AUTOMOTIVE OEM
When a major automotive OEM needed full-length side storage cargo boxes for their light duty pickup, they turned to us to push the limits of blow molding capability. At 6’7”, these boxes are some of the industry’s largest blow molded automotive parts.
The Challenge
MANUFACTURING AND LIGHTWEIGHTING: DESIGN FOR MAXIMUM DURABILITY AND MINIMAL ASSEMBLY
Design and manufacture lightweight, full-length plastic cargo boxes that meet all OEM performance requirements. In addition, they need to fit over the wheel wells and utilize the bed space very efficiently, maintaining enough space for larger items like 4’x6’ drywall and other building materials to be stored in the bed.
The solution
TWO-PIECE DESIGN, ENHANCED MATERIAL PROPERTIES, AND ONE-PIECE FLOW ASSEMBLY
Utilizing glass-filled polypropylene, the boxes and lids are blow molded in color (MIC) with graining to achieve the required durability and surface finish.
Next, the holes are drilled, and excess material is trimmed.
Finally, the cargo box is assembled using a one-piece flow in which both the boxes and lids move down the assembly line parallel to each other to install the latch bezel, handle, weather seals, and secondary seals.
The Result
AN INNOVATIVE CARGO BOX NOMINATED FOR AUTOMOTIVE INNOVATION AWARD
An innovative new take on truck cargo boxes: a lightweight, structurally sound, completely sealed cargo box that’s easy to install and maximizes the storage space in a truck bed. Impressed with the results, the OEM nominated the truck cargo box for the SPE Automotive Innovation Award – Aftermarket Category.
BLOW MOLDING DESIGN GUIDE
Are you new to blow molding and don’t know where to start with your part design? Then our Blow Molding Design Guide is for you! Created by engineers, for engineers, this guide is the ultimate starting point to kick off a successful product design for the blow molding process.
