Abstract: A vehicle includes a body, a bumper and a plurality of self-tapping fasteners. The body defines mounting orifices. The bumper has an exterior shell that includes an interior wall. The interior wall has receiving portions that protrude inward relative to the shell such that the receiving portions are thicker than adjacent portions of the interior wall. Each of the plurality of self-tapping fasteners extend through one of the orifices and into one of the receiving portions to secure the bumper to the body.

Abstract: A vehicle includes a body, a bumper and a plurality of self-tapping fasteners. The body defines mounting orifices. The bumper has an exterior shell that includes an interior wall. The interior wall has receiving portions that protrude inward relative to the shell such that the receiving portions are thicker than adjacent portions of the interior wall. Each of the plurality of self-tapping fasteners extend through one of the orifices and into one of the receiving portions to secure the bumper to the body.

Abstract: Blow molded components and systems and methods for forming the same are disclosed. The blow molded component may be an air duct, for example, a structural air duct. The structural air duct may include a hollow main body including a first layer of a first material and a second layer of a second material surrounding the first layer. At least one hollow protrusion may extend from the hollow main body and may include proximal and distal portions. The proximal portion may include the first layer surrounded by the second layer and the distal portion may include only one of the first and second layers. The duct may be formed by blow molding a multi-material parison. The first and second materials may have different tensile moduli, and during the molding process the material with the higher modulus may tear and allow the lower modulus material to fill the protrusion.