DETROIT -- General Motors is using film rather than paint on parts for five vehicles. Bumper fascia and rocker panels are among the parts involved.

Unlike past users of paint replacement film on parts, GM has chosen a thick thermoformed sheet. The company intends to develop a supply base of thermoformers.

"This is one of our major efforts," said Charles Buehler, a technical integration engineer in GM's materials group, during an Oct. 11 interview at the Society of Plastics Engineers' Thermoplastic Olefin conference in Sterling Heights, Mich. "We're working to build a cooperative supply base for thermoforming."

GM first used a thermoformed sheet that combined a thermoplastic polyolefin base with a body-color film on a stone shield for its Chevrolet SSR pickup. Now the Chevrolet HHR wagon has stone shields that were made using the process.

Two cars just beginning to roll out -- the Buick Lucerne and Cadillac STS-V -- have thermoformed rocker panels; the GMC Envoy will have thermoformed bumper fascia starting next year.

GM and its suppliers have created 1,000 of the fascia in an early rollout. With the bumpers, not only did the companies eliminate the need to paint a plastic part, they also replaced an injection-molded part with thermoforming.

An earlier paint-replacement system that debuted on the Dodge Neon used thermoformed paint replacement, but the fascia was injection molded behind a thin formed sheet.

The thick-sheet thermoforming reduces the number of manufacturing steps, which shortens development time and cuts costs. That's because tooling for thermoforming is less expensive than standard injection-molding tooling, Buehler said.

Using thermoforming, the company and its suppliers can create a component -- from design to tooling to production -- within 120 days, he said.

"We see this as an enabler," Buehler said. "We're not against injection molding behind (the sheet), but we think the supply base in place isn't ready."

Now a supply base for thermoforming is developing, creating opportunities for molders, material suppliers, tool makers and machinery makers.

The GM system uses films produced by Soliant LLC of Lancaster, S.C., that can match the full line of automotive paint colors.

Machinery makers accustomed to making materials-handling equipment are learning how to make parts that meet automakers' demands for Class A surface quality, said Ed Bearse, a partner in Plastic Concepts & Innovations LLC of Mount Pleasant, S.C.

His company helps coordinate communication within the developing supply chain and runs training programs for thermoformers.

Suppliers latch on

Durakon Industries Inc., a Lapeer, Mich., supplier that makes aftermarket thermoformed pickup beds, launched its paint film technology with the SSR. Now it's turning out rocker panels for the Lucerne and STS-V.

Guardian Industries Inc., of Auburn Hills, Mich., a traditional injection molder, is making the stone shields for the HHR. It is taking over thermoforming operations from partner Southtech Plastics Inc. of New Bern, N.C., and is seeking more contracts.

Another injection molder, Meridian Automotive Systems Inc., of Dearborn, Mich., is overseeing the SUV fascia program.

"This is something new for the industry," said Len Damico, vice president of sales at Durakon. "It's been a real bright spot for the company, and we've made some substantial investments."

Durakon was one of a handful of thick-sheet thermoformers that already supplied the auto industry. It had its own in-house extrusion to turn out the sheets but added clean rooms to laminate its substrate to Soliant's film. It also added robots to automate production further.

"It had been a tremendous effort to get this started from an infrastructure standpoint," said Joe Randazzo, Guardian's director of research and materials development.

By partnering with Southtech, Guardian has access to Southtech's expertise in producing the thick thermoplastic polyolefin sheets laminated with Soliant's film. It is also tapping other companies, such as Plastic Concepts & Innovations, for information.

Durakon has shared information with potential competitors to get the industry off to a smooth start, Damico said. "It's a new beast out there called collaboration," he said. "Collaboration and teamwork are essential."

Selected applications

GM is targeting specific applications on each vehicle it has selected for its paint-replacement project, Buehler said. In the case of the HHR, the company needed to protect a fender area of the car that takes abuse from road debris. Stones would chip away the paint on a standard part.

GM and its suppliers had to design a shield that would stand up to the damage but also precisely mimic the shape of the vehicle, sitting flush with the body.

"The perspective that we're looking at is in terms of value performance," Buehler said. "We want what's best for the vehicle. We want the right places to do it."

Meridian is investing both in thermoforming and standard injection molding and paint lines so that it can make parts with whichever process a customer selects, COO Steve McKenzie said.

Success with GM's programs now will lead to more opportunities. Guardian's Randazzo said all of the automakers are continuing to consider options.

Said Randazzo: "There is a lot of interest out there, and GM, for all intents and purposes, is the one that is pushing it forward."