The 2003 Dodge Viper's incredible power requires aerodynamic stability. Unlike most vehicles, the Viper has an underbody tray that smoothes airflow and creates aerodynamic downforce that improves handling. It also protects vital components from dirt and debris. Engineers at Mayco Plastics in Sterling Heights, Mich., looked for the best combination of impact resistance and light weight for the front and rear portions of the tray - also known as the belly pan.
The solution was to mold the approximately 2-ft. x 5-ft. parts from Twintex commingled thermoplastic composite from Saint-Gobain Vetrotex America. "The Twintex material is light, but very impact resistant. It can flex and bounce back, unlike aluminum, which dents, and straight polypropylene, which can crack," said Mark Ryskamp, a Mayco engineer. To create a uniform black finish, Mayco laminates a polypropylene film to the Twintex® material during the thermoforming process. "It really is a home run for this part," Ryskamp added.
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