BETAFOAM* structural polyurethane foam is molded into pre-formed geometries and, when cured, is overmolded with BETAMATE* structural adhesive using a Dow Automotive proprietary resin transfer molding process. The SFIs nest seamlessly into sheet metal cavities and the epoxy adhesive expands and rigidly bonds the foam parts to the surrounding steel structure during plant bake processes.

SFIs from Dow Automotive are currently in use on several GM vehicles including in the upper center pillar area of the 2005 Buick LaCrosse.

Dow Automotive's work on the 2005 Buick LaCrosse helped benchmark the capabilities of the SFI technology. Development was executed in parallel with the OEM program timing and vehicle development process milestones, including:

• Initial finite element analysis performance predictions
   
• CAE and design
   
• Prototype development and hardware testing
   
• Product validation
   
• Manufacturing process development and scale-up

"The SFIs recently commercialized by Dow Automotive offer customers the benefit of combining traditional BETAFOAM polyurethane foam solutions with the convenience of easy to install pre-formed parts," said Paul Juras, Market Development Manager for Dow Automotive. "We leveraged our experience in materials science with our engineering capabilities to create a parts solution that integrates multiple Dow Automotive bulk material technologies. We're confident that these structural foam inserts can be designed to support a wide variety of vehicle architectures and application requirements."

BETAFOAM polyurethane foams and BETAMATE structural adhesives are two of many Dow Automotive solutions that can be used to enhance the effectiveness of vehicle body structure without adding weight or significant cost.

Dow Automotive is a leading supplier of plastics, adhesives, sealants and other plastics-enhanced solutions for interior, exterior, under-the-hood, vehicle body structure and acoustical management applications. The organization serves global tier, OEM and aftermarket customers. With offices and application development centers around the world, Dow Automotive provides materials science expertise and comprehensive technical capabilities to its customers worldwide. For additional information about Dow Automotive products and services, visit www.dowautomotive.com.