Husky Injection Molding Systems has taken its rotary tooling Index technology beyond traditional packaging applications, now enabling the production of two-component automotive parts. This shift marks a significant expansion for the company, which is based in Bolton, Ontario. Lear Corp. recently acquired a 3,500-ton extruder featuring Husky's QTI (Quadloc-Tandem-Index) system, specifically designed to mold dual-layer automotive dashboards. The outer layer, made from thermoplastic elastomer (TPE), provides a soft-touch finish, while the inner layer uses polypropylene or thermoplastic olefin (TPO). Potential applications also include door trim panels, sun visors, consoles, and interior components.
At a press event held at the Husky Technology Center in Novi on June 29, both companies showcased the QTI machine. The system features two injection units aligned in a straight line. One unit molds the dashboard base, while the Swing Index module rotates the second mold into position, allowing the TPE to be molded onto the surface. This single-step process replaces the traditional method that required up to 10 steps, significantly improving efficiency.
Kenneth Shaner, a senior executive at Lear’s automotive interiors division in Dearborn, Michigan, described the QTI technology as a "new epoch-making innovation." He was impressed by the machine’s ability to create seamless, noise-free parts. "This will change the rules of the game," he said. According to Shaner, multi-material molding is becoming a key trend in large automotive components, with promising future applications.
Lear has already secured three contracts using this technology: one for a TPE surface with a polypropylene underlay, another for a TPO door panel, and a third for an instrument panel with a TPE surface and TPO base. These projects are set to launch in the coming years.
The integrated design eliminates common issues like noise caused by plastic-to-plastic friction. It also allows for larger structural ribs and consistent color matching between left and right components. This level of precision and integration is transforming car interior manufacturing, making it more efficient and visually cohesive.
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