Abstract: A fail safe module for an active grille having two or more vanes movable between an open position and a closed position. In the event of failure of an electrically driven actuator, a fail safe module connected between a driven vane of the two or more vanes and the electrically driven actuator moves the vanes to a fail-safe position. The fail safe module has a locked and unlocked position. When the fail safe module is in the locked position the fail safe module, the electrically driven actuator and the two or more vanes move together in response to the power provided by the electrically driven actuator. When the fail safe module is in the unlocked position, the fail safe module disengages the two or more vanes from the electrically driven actuator and moves the two or more vanes to the fail-safe position.

Abstract: A bumper assembly includes a bumper beam for absorbing an impact of a vehicle and a crash box attached to the bumper beam and extending along an axis A. A mounting plate is attached to the crash box and defines at least one lateral slot extending laterally along the mounting plate in spaced and perpendicular relationship to the axis A. A fastener extends through the lateral slot for mating with a mounting surface of the vehicle frame to establish a secured position of the bumper assembly. The fastener includes a shoulder disposed in abutting relationship with the mounting surface in the secured position to dispose the mounting plate and the mounting surface in spaced relationship to one another for allowing the fastener to slide laterally along the lateral slot during a vehicle impact to reduce the transfer of lateral impact forces from the bumper assembly to the vehicle frame.

Abstract: An apparatus for forming a three-dimensional (3D) object includes a 3D printing head, for fabricating a first portion of the 3D object by forming a plurality of successive layers of a first material. The apparatus also includes a delivery head for fabricating a second portion of the 3D object by dispensing onto the first portion of the 3D object a plurality of layers of a continuous-fiber reinforced second material. Further, the delivery head includes comprising a roller for pressing the continuous-fiber rein-forced second material into place during the dispensing thereof. A controller controls the 3D printing head and the delivery head to cooperatively form the 3D object, based on a dataset corresponding to a 3D object model.

Abstract: A roll forming assembly for forming a transverse strut from a tube is provided. The roll forming assembly includes a heater, such as an induction heater, for heating a tube to a predetermined annealing temperature. Next, the tube is fed to a roll former, which includes a plurality of forming wheels to shape the tube into a transverse strut. Servo motors are operably coupled to the forming wheels for adjusting the positions of the forming wheels in a radial direction during the roll forming process to give the transverse strut a variable profile along its length. After the roll forming process is completed, the transverse strut is quenched so that its base material is given a predetermined microstructure.

Abstract: An automotive component including a composite casting is provided. The composite casting includes a steel member and an end cap fastened to an end portion of the steel member. A cast coupling member is cast about the end portion of the steel member including the end cap, thereby positively and rigidly securing the cast coupling member to the steel member. The automotive component can comprise an engine cradle, a control arm, an instrument panel support structure, a bumper assembly, or a twist axle. The cast coupling member is typically formed by casting-in-place aluminum about the end cap and the end portion of the steel member. The steel member is typically a tubular member, and the end cap typically includes a flange designed to provide a mechanical interlock surface with the cast coupling member. For example, the flange can have a polygonal shape, an outwardly extending member, or notches.

Abstract: A twist beam (22) for a suspension assembly (20) comprises a base portion (44) and side walls (46) presenting an open U-shaped cross-section and a bulged middle section (24). The twist beam (22) includes end sections (56, 58), the middle section (24), and transition sections (60, 62) each extending from one of the end sections (56, 58) to the middle section (24). The width (w) and the height (h) of the twist beam (22) increase along the transition sections (60, 62) to the middle section (24). The width (w) and the height (h) of the middle section (24) are greater than the width (w) and the height (h) of the end sections (56, 58). The cross-sectional area of the bulged middle section (24) is typically 10% to 30% greater than the cross-sectional area of the end sections (56, 58).

Abstract: A mounting structure for a solar panel assembly, having a plurality of solar panels, includes a plurality of vertical support legs and a grid assembly. The grid assembly includes a plurality of north-south members and the east-west members. The plurality of north-south members include a plurality of elongated slots to allow attachment to the vertical support legs despite any manufacturing tolerances that may exist in the components. The plurality of east-west members include a plurality of elongated slots to allow attachment to the north-south members despite any manufacturing tolerances that may exist in the components.

Abstract: A stacked transparent lighting arrangement for a vehicle interior trim component. The vehicle interior trim component can be any trim component or visible surface in the interior of a vehicle. Examples include but are no limited to an instrument panel, arm rest, glove compartment door, door trim piece, headliner, foot pedal or seat cover. The lighting arrangement includes a housing forming part of the vehicle interior trim component. On or more layers of transparent optics contained in the housing with a appearance formed each of the one or more layers of transparent optics. The appearance can be any type of numbers, letters, graphics or other indicia, including but not limited to words, logos or designs.

Abstract: A liftgate cargo module having an integrated tailgate that unfolds from a hatch or liftgate of a vehicle that adds additional storage and provides a cargo load floor. When unfolded, there is an integrated pass through door formed in the hatch or liftgate permiting longer items to be hauled, while keeping the hatch or liftgate completely closed. The integrated tailgate includes an integrated tailgate taillight that indicates when the vehicle is braking or backing up. The integrated tailgate taillight also helps to show that the integrated tailgate is folded down from and extending from the hatch or liftgate of the vehicle. The integrated tailgate also includes integrated anchor points formed on the cargo load floor so items may be tied down and secured. An all-weather enclosure that is connectable to the cargo load floor for enclosing contents that are being hauled on the integrated tailgate may also be provided.

Abstract: A wiper module assembly for a vehicle lift gate having an inner panel with a spoiler formed as a one-piece part of an outer panel. The outer panel of the lift gate is connected to the inner panel to form an exterior surface of the lift gate. A cavity is formed in part of the spoiler and receives a carrier forming a removable module connected to the cavity of the vehicle lift gate. The carrier includes a wiper, motor and drive assembly for operating a wiper for a window on the lift gate.

Abstract: An apparatus and method for upsetting an end of a hollow workpiece to increase the wall thickness of that end is taught. A mandrel is inserted into the workpiece within a clamp which holds the workpiece. A die is urged into contact with the end of the workpiece to compress the end, decreasing its length and increasing the wall thickness of the end while the mandrel and clamp prevent deformation of the workpiece held in the clamp.

Abstract: A hybrid laser arc welding assembly including a gas metal arc welding torch and a laser arc welding laser head. The torch and laser head are disposed adjacent one another and aimed at targets of a pair of work pieces spaced from one another such that the melted material produced by the torch overlaps with the melted material produced by the laser head, and therefore, the torch and laser head combine to create a hybrid laser arc weld to join the work pieces. The laser head is adjustable dynamically relative to the work-pieces to optimize the hybrid laser arc weld.

Abstract: An active grille shutter arrangement having a modular frame. The active grille shutter arrangement includes a primary frame piece defining a width and height of an aperture of the modular frame, wherein in the primary frame piece has a motor housing, and upper frame portion having a first end and a second end, a lower frame portion having a first end and a second end and the motor housing extends between the upper frame portion and the lower frame portion. There is a plurality of secondary frame pieces. The modular frame of the active grille shutter arrangement is formed by the connection of the primary frame piece in the secondary frame piece, wherein the modular frame defines the aperture. The active grille shutter arrangement further includes a plurality of vanes rotatably positioned between the first end cap and the second end cap for controlling the amount of air flowing through the one or more apertures of the modular frame.

Abstract: Cooling apparatus having a cooling box with integrated cooling and attachment features providing end of arm tooling to demold and cool molded parts. There is provided a net fit between a porous tool nest portion of the cooling box and the molded part being manufactured to allow the cooling cycle time to be reduced as the molded part finishes the cooling cycle in the end of arm tooling while a mold is closed and starts making the next molded part. The cooling box is connected to at least one vacuum line having a vacuum unit to generate a vacuum allowing for part demolding and cooling. The fully assembled form fitting cooling box is 3D printable to effectively create a partially solid and partially microporous cooling box.

Abstract: A headlamp assembly for projecting light in a forward direction along an optical axis is provided. The headlamp assembly may include a housing, a low beam light emitting device, a high beam light emitting device, a low beam lens, a high beam lens, and a reflector. The low beam and high beam light emitting devices may be arranged in the housing and include first and second planar surfaces, respectively, from which light is emitted. The normal to the first and second planar surfaces may be oriented away from the optical axis at substantially forty-five degrees in relation to the optical axis. The normal to the second planar surface may be oriented away from the normal to the first planar surface at substantially ninety degrees.

Abstract: A process for making a shaped-part from a heat-treatable aluminum alloy blank comprises providing the blank in a hardened temper state, for instance the T6 or another suitable temper state. The as-provided blank is subjected to selective heating, such that a first portion of the blank is heated to a predetermined first temperature for a predetermined first length of time and a second portion of the blank is heated to a predetermined second temperature for a predetermined second length of time. The heated blank is then formed into the desired shape of the shaped-part, and is cooled to ambient temperature. The selective heating substantially increases ductility to facilitate forming of the blank into the desired shape of the shaped part, and provides desired mechanical properties within first and second portions of the shaped part corresponding to the first and second portions of the blank.

Abstract: A thermoplastic liftgate inner panel construction is provided by using a co-injected injection molding process. In a first phase, a class A surface material is injected into the molds and thereafter in a second phase an inner core of material is injected using a gas-infused reinforced polymer.

Abstract: A sub-frame assembly for attachment to a unibody of a vehicle and for supporting at least one vehicular component is provided. The sub-frame assembly includes a pair of longitudinal members which are spaced from one another in a lateral direction and extend in a longitudinal direction between first and second ends. The longitudinal members at least partially converge towards one another from the first ends to the second ends such that the second ends are closer to one another than the first ends. A cross-member is coupled with and extends laterally between the longitudinal members. Each of the longitudinal members and the cross-member has a single and no more than one body mount for connection with the unibody of the vehicle such that the sub-frame assembly has exactly three body mounts in total.

Abstract: A nanofluid molding arrangement includes a mold tool (12) having movable pieces (14, 16) that move between an open and closed position. When the moveable pieces (14, 16) are in the closed position, they form a mold cavity (18) that defines a surface for creating a molded part. The nanofluid molding arrangement also includes at least one injection port (22) for injecting molten resin directly into the mold cavity (18) such that when molten resin flows into the cavity and begins to cool, the molded part begins to form. After the molded part begins forming and injection of the molten resin is stopped, a nanofluid having a colloidal suspension of thermally conductive nanoparticles suspended in an aqueous or organic solution is applied to the mold tool (12), through at least one cooling port, to wick away or draw heat out and cool the mold cavity and the formed part within the mold cavity (18).

Abstract: An active grille shutter arrangement having an assembled modular frame. The assembled modular frame includes an upper frame portion and a lower frame portion each having a first end and a second end. A first end cap is connectable to both the first end of the upper frame portion and the first end of the lower frame portion. The connection between the first end of the upper frame portion and the first end of the lower frame portion includes an upper bar end joint formed on the front end of the upper frame portion and a lower bar end joint formed on the first end of the lower frame portion. The upper bar end joint slides into an upper bar end cap joint formed on the first end cap and the lower bar end joint slides into a lower end cap joint formed on the first end cap.