When a leading OEM faced a 50% premature failure rate in its front aero shield, it was clear that the existing PET-based solution, while effective against stone chipping, lacked the abrasion resistance to survive real-world road conditions. From rough urban streets to snow-packed highways, the shield was wearing out far sooner than expected, leading to costly warranty claims and undermining customer satisfaction.
The Challenge
The existing aero shield, made from PET (Polyethylene Terephthalate) with fibrous reinforcement, had proven effective at absorbing impacts from stones and debris. However, the same fibrous composition that made it impact-resistant also left it vulnerable to abrasion from concrete, speed bumps, and high-friction surfaces. Environmental stressors such as temperature variations, snow accumulation, and moisture in the air accelerated the wear process. The challenge was to maintain OEM ground clearance standards and aero performance while dramatically improving wear resistance and structural integrity.
Goken Methodology
The development process began with an environmental load study, capturing real-world data on temperature variations, snow load impact, and ground clearance performance during dynamic driving. This formed the basis for a rigorous material selection and testing phase in which PET, PET+PP hybrid, PP (Polypropylene), and GMT (Glass Mat Thermoplastic) were compared for their abrasion resistance, weight, and compatibility with existing aerodynamic requirements.
Abrasion testing revealed a stark difference: while PET offered baseline durability, GMT delivered a staggering 55 X improvement in wear resistance. Advanced CAE snow load analysis confirmed that GMT could limit deflection to less than 15 mm under extreme conditions and hence outperforming all alternatives. Prototype parts were then produced and subjected to physical abrasion tests and fitment trials, validating the digital simulations with tangible real-world results. decision matrix evaluation analysis helped compare various paramters such as abrasion resistance, weight, tooling investment, cost, and snow load performance. Despite slightly higher weight and cost, the GMT-based design emerged as the clear winner.
Impact & Results
The transition to GMT technology marked a leap forward in OEM durability standards. Abrasion resistance improved from negligible baseline levels to 55 times greater performance, ensuring that the shield could withstand years of real-world driving without degradation. Snow load deflection was reduced to less than 15 mm, reinforcing structural stability in harsh winter conditions.
The product’s lifespan extended significantly, cutting down replacement frequency and reducing warranty claim rates. This improvement not only lowered operational costs for the OEM but also strengthened end-user trust in the brand’s commitment to long-term quality. Crucially, all enhancements preserved aerodynamic efficiency and ground clearance, safeguarding both performance and design integrity.
