Custom automotive dashboard plastic parts serve as the core human-machine interface in vehicles, directly influencing driving safety, display clarity, and service life. By precisely matching the properties of high-performance engineering plastics with dashboard functional requirements and integrating advanced molding technologies and intelligent designs, we establish a full-process solution from material selection to mass production, meeting diverse customization needs for dashboards in passenger vehicles, commercial vehicles, and new energy vehicles.
Custom Automotive Dashboard Plastic Parts

I. Core Material Properties and Application Advantages

(A) Comparison of Mainstream Material Properties

Material Type
Density (g/cm³)
Temperature Resistance (℃)
Haze (%)
Flammability Rating (UL94)
Core Advantages
Typical Certifications
Polycarbonate (PC)
1.20
-40~130
≤1.5
V-2
High transparency, impact resistance, dimensional stability
ISO 179 Impact Resistance Certification
Acrylonitrile Butadiene Styrene (ABS)
1.05
-20~80
≤3.0
V-0 (1.6mm)
Easy molding, cost-effective, easy electroplating
UL 746C Material Certification
Polybutylene Terephthalate (PBT)
1.31
-40~150
≤2.0
V-0 (0.8mm)
Low hygroscopicity, chemical resistance
IEC 60695-2-11 Glow Wire Test Certification
PC/ABS Alloy
1.15
-30~120
≤2.5
V-0
Balanced high strength and temperature resistance
RoHS Environmental Certification
Thermoplastic Polyurethane (TPU)
1.20
-50~80
≤5.0
HB
Elastic touch, low-temperature impact resistance
SAE J2005 Weather Resistance Certification

(B) Driving Forces of Customization Requirements

1. Safety and Reliability

  • High-temperature Resistance: No deformation after long-term use at 120℃, heat deflection temperature ≥130℃ (HDT test).
  • Flammability Requirement: Dashboard body material flammability rating ≥UL94 V-0 (3.0mm thickness) to prevent fire spread.
  • Impact Resistance: Impact strength ≥50kJ/m² at -40℃, complying with FMVSS 201 vehicle safety standards.

2. Display and Interaction Performance

  • Optical Performance: Transmittance ≥85% (display area), haze ≤2% to ensure clear visibility.
  • Surface Hardness: ≥3H (pencil hardness test), resistant to 1000 friction cycles without obvious scratches.
  • Sensor Integration: Pre-installed slots for cameras/radars with dimensional tolerance ±0.05mm to guarantee signal accuracy.

3. Environmental Adaptability

  • Weather Resistance: QUV-A aging test for 2000 hours, color difference ΔE≤3, strength retention ≥80%.
  • Chemical Resistance: Resistance to common automotive liquids (e.g., windshield washer fluid, sunscreen) for 72 hours without swelling/discoloration.

II. Analysis of Five Core Processing Technologies

(A) Injection Molding: High-Precision Structural Processing

  • Technical Advantages
    • Enables one-step molding of complex curved surfaces (e.g., arched dashboard shells, embedded display slots) with dimensional accuracy ±0.03mm.
    • Large-scale molds (1-2 cavities per mold) suitable for 10-15kg dashboard assemblies, production efficiency 100-200 pieces/hour.
  • Process Parameters
    • Injection pressure 150-200MPa, mold temperature 80-120℃ (for PC), cooling time 25-40 seconds.
    • Shrinkage control: PC 0.5%-0.8%, PC/ABS 0.6%-1.0%, ensuring assembly gap ≤0.1mm.

(B) Surface Treatment Technologies

Process Type
Typical Application Scenarios
Technical Highlights
In-Mold Decoration (IMD)
High-end dashboard matte/metallic finishes
Pattern precision ±0.05mm, weather resistance increased by 30%
Anti-Glare Coating
Display protective covers
Haze control 5%-15%, reflectance ≤5% (60° angle measurement)
Electroplating
Decorative buttons/bezels
Chrome plating thickness 8-12μm, salt spray test ≥500 hours
Laser Texturing
Anti-slip control areas
Surface roughness Ra 1.6-3.2μm, friction coefficient increased by 25%

(C) 3D Printing: Rapid Prototyping and Small-Batch Customization

  • Process Advantages
    • Rapid validation of irregular structures (e.g., curved dashboards, hidden air vents), samples delivered in 3 days.
    • Nylon 12CF material strength up to 150MPa, supporting functional tests (e.g., clip fatigue testing).
  • Technical Parameters
    • Layer thickness 0.05mm, dimensional accuracy ±0.1mm, suitable for high-precision sensor slot validation.
    • Supports transparent/translucent material printing for display optical performance testing.

(D) Secondary Processing: Functional Integration

  • Structural Reinforcement
    • Metal insert molding (e.g., copper mounting nuts), pull-out force ≥200N to ensure secure dashboard-vehicle connection.
    • Ultrasonic welding strength ≥30MPa for seamless multi-component bonding (e.g., dashboard body and sun visor).
  • Intelligent Integration
    • Integrated capacitive touch areas with response time ≤10ms, position accuracy ±0.2mm.
    • Light guide strip embedding technology for uniform ambient lighting (brightness difference ≤5%).

(E) Thermoforming: Curved Glass Bonding Technology

  • Technical Advantages
    • Achieves 2.5D/3D curved glass bonding with plastic substrates, bonding accuracy ±0.1mm.
    • Temperature resistance up to 130℃ for long-term use in high-temperature dashboard environments.
  • Key Parameters
    • Bonding pressure 5-10N/cm², bubble rate ≤0.1% (area ≥1mm²).
    • Edge bonding strength ≥50N/mm to prevent glass detachment.

III. Full-Process Customization Solutions

(A) Design and Material Engineering

1. Multi-Dimensional Design Support

  • Optical Design
    • Display area uses PC material with optimized transmittance up to 90%, paired with anti-glare coatings to reduce reflection.
    • Analog dashboard scale accuracy ±0.5°, ensuring reading error ≤1%.
  • Structural Optimization
    • Moldflow simulation analyzes shrinkage rate, rib thickness designed at 1.5-2.5mm, deformation ≤0.2mm.
    • Lightweight design: Micro-foam injection technology reduces weight by 15%-20% compared to traditional designs.
  • Intelligent Integration
    • Pre-installed slots for ADAS sensors (e.g., cameras, radars) with position accuracy ±0.03mm.
    • Integrated tactile feedback modules with key travel 3-4mm and feedback force 15-25N.

2. Precise Material Selection

  • Economy Passenger Vehicles: ABS + 20% flame retardant, balancing cost and basic performance (V-0 flame retardancy, 80℃ temperature resistance).
  • High-End Models: PC/ABS alloy + IMD process for high-gloss surfaces and 120℃ long-term temperature resistance.
  • New Energy Vehicles: PBT + 30% glass fiber for battery compartment heat resistance (150℃ short-term tolerance) and EMI shielding.

3. Pre-Processing Technology

  • Raw material drying: PC moisture content controlled ≤0.02% to avoid post-molding optical defects.
  • Color calibration: Datacolor spectrophotometer ensures Pantone color matching accuracy ΔE≤0.8.

(B) Production and Quality Control

1. Flexible Manufacturing Capability

  • Rapid Prototyping
    • 3D printed samples delivered in 48 hours, aluminum mold development cycle 15-20 days (steel mold 40-50 days).
    • Supports minimum order quantity of 50 pieces for new vehicle R&D needs.
  • Mass Production
    • Automated production lines: KUKA robots handle bonding and inspection, daily capacity 500-1000 pieces per line.
    • Intelligent warehousing: QR code traceability ensures batch qualification rate ≥99.2%.

2. Comprehensive Inspection System

  • Optical Performance
    • Transmittance/haze test: Complies with ISO 13468, display area transmittance ≥85%.
    • Color difference detection: Spectrophotometer measurement, ΔE≤1.0 (matching vehicle interior).
  • Mechanical Performance
    • Vibration test: 10-2000Hz sweep, 5g acceleration, no looseness/deformation (SAE J1455 standard).
    • Fatigue test: Key life ≥50,000 cycles, clip insertion force decay ≤10%.
  • Environmental Performance
    • Thermal shock: -40℃~85℃ cycling 50 times, dimensional change rate ≤0.15%.
    • Chemical resistance: 5% NaOH solution immersion for 24 hours, surface hardness retention ≥95%.
  • Certification Support: Provides IATF 16949, UL, ECE R118, and other certification reports.

IV. Multi-Scenario Application Solutions

(A) Passenger Vehicle Sector

  • Traditional Fuel Vehicle Dashboards
    • Uses ABS/PC alloy with IMD process for wood/metal 拉丝 (brushed) finishes, 120℃ temperature resistance for engine bay heat conduction.
    • Integrates mechanical gauges and LCD displays, mounting hole accuracy ±0.1mm for seamless center console integration.
  • New Energy Vehicle Full-LCD Dashboards
    • High-transparency PC material with 2.5D curved glass, anti-glare coating reduces sunlight reflection, edge radius R≥5mm for improved visual appeal.
    • Lightweight design (weight ≤1.5kg), micro-foam structure reduces plastic usage by 20% for battery range optimization.

(B) Commercial Vehicle Sector

  • Truck Dashboards
    • PBT + 30%GF material, 150℃ temperature resistance for cab high-temperature environments, anti-vibration design (natural frequency ≥200Hz).
    • Laser-textured large button areas with wet-hand friction coefficient ≥0.6 for enhanced driving safety.
  • Bus Dashboards
    • TPU elastic frame + PC body, no brittle fracture under -40℃ impact, IP54 dust/water resistance for complex road conditions.

(C) Smart Cockpit Sector

  • AR-HUD Dashboards
    • Optical-grade PC material, transmittance ≥92% and birefringence ≤5% to ensure distortion-free AR images.
    • High-precision mold forming (tolerance ±0.02mm) for HUD projector installation.
  • Touch-Integrated Dashboards
    • Capacitive touch areas using PC/ABS alloy with surface hardening (hardness ≥4H), supports gloved operation (response sensitivity ≥80%).

V. Technology Selection Guide

Requirement Type
Preferred Technology Combination
Material Selection
Core Indicators
Delivery Cycle
New Vehicle R&D Validation
3D Printing + IMD
PC/ABS Alloy
Rapid prototyping, optical performance verification
Prototype in 5 days, small batch in 20 days
High-End Appearance Customization
Thermoforming + Electroplating
PC
Curved glass bonding, high weather resistance
Prototype in 7 days, mass production in 30 days
Large-Scale Standardized Production
High-Speed Injection Molding + ABS
ABS
Low cost, high production efficiency
Prototype in 5 days, mass production in 25 days
New Energy High-Temperature Demand
Micro-Foam Injection + PBT
PBT
Lightweight, 150℃ long-term temperature resistance
Prototype in 7 days, mass production in 35 days
Custom automotive dashboard plastic parts achieve full-category coverage from traditional analog to fully digital smart dashboards through deep integration of material properties, processing technologies, and vehicle functions. Whether meeting the durability needs of fuel vehicles or the lightweight and intelligent requirements of new energy vehicles, our full-process technical capabilities ensure each customized solution precisely meets standards for optical performance, mechanical strength, and environmental adaptability.
For custom solutions using PC/ABS/PBT materials, certification testing processes, or production capacity data, contact us for professional support from design development to mass production.

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