Skip to main content

Development of Crash Pad Using Overmolding Technology


Herein, the hard panel-crash pad Integrally overmolded with soft skin thermoplastic polyoefins (TPO) for soft feeling and cost reduction was developed. Furthermore, a cost-effective PAB door system having an in-mold tear seam was produced that avoided competitors’ patents simultaneously. The development procedure of this overmolding technology was introduced as follows. The first one is the selection of overmolding material. The second one is the design optimization. The third one is the solving of the tool challenges. The reduction in the number of process by integrally molding with soft material helped accomplish a soft feeling on the crash pad and cost reduction simultaneously. The airbag deployment as well as head impact performance and heat-aging tests were conducted and applied to five patents for optimizing the mold’s structure and injection conditions.

This is a preview of subscription content, access via your institution.


  • Clark, C. L. and Locke, D. J. (1996). High strain rate testing of engineer thermoplastics for head impact applications. SAE Paper No. 960153.

  • Das, J. (2001). Modeling methodology of tearseams for invisible PSIR systems. SAE Paper No. 2001-01-0314.

  • Goral, T. (2000). Materials modeling for engineering thermoplastics in FEA under high-strain loading. SAE Paper No. 2000-01-1167.

  • Goral, T., Nagaswamy, V. and Schlenke, R. (1999). A predictive design methodology for active top pads during airbag deployment. SAE Paper No. 1999-01-0688.

  • He, S. X. (1997). Advanced finite element analysis in the structural design of airbag modules. SAE Trans., 1298–1309.

  • Kim, M. K. and Huh, H. (2019). Asymmetric hardening behavior of AZ31B magnesium alloy sheet with large strain at various strain rates. Int. J. Automotive Technology 20, 4, 645–653.

    Article  Google Scholar 

  • Kong, B. S. and Park, D. K. (2018). Design optimization of the cowl cross bar-light cowl cross bar satisfying 5 performances. Int. J. Automotive Technology 19, 3, 387–391.

    Article  Google Scholar 

  • Kong, B. S. and Park, D. K. (2019). Invisible PAB door development using two-shot molding. Int. J. Automotive Technology 20, 2, 221–225.

    Article  Google Scholar 

  • Kong, B. S., Park, J. G. and Bae, J. S. (2004). Invisible advanced passenger-side airbag door design for optimal deployment and head impact performance. SAE Paper No. 2004-01-0850.

  • Kong, B. S., Park, J. G. and Lee, D. W. (2002). The effects of various design factors for invisible passenger-side airbag door opening. SAE Paper No. 2002-01-0184.

  • Kulkarni, K. B., Kuschinsky, S. D. and Thyagarajan, R. S. (1997). Using CAE to guide passenger airbag door design for optimal head impact performance. SAE Paper No. 970772.

  • Malczyk, A., Franke, D. and Adomeit, H. D. (1998). Dual-stage inflators and OoP occupants — A performance study. SAE Trans., 2438–2445.

  • Nagaswamy, V. and Goral, T. (1999). Material characterization and FEA correlation for engineering thermoplastics under high strain loading. SAE Paper No. 1999-01-3175.

  • Naughton, P. (1999). Extension of material models and finite element techniques to improve the simulation of high speed impact of thermoplastic materials. SAE Trans., 216–220.

  • Xiao, X. (2002). Plastic material modeling for FMVSS 201 simulation. SAE Paper No. 2002-01-0385.

  • Woodman, D., Das, J. and Patel, S. (2001). Predicting material processing degradation. SAE Paper No. 2001-01-1273.

  • Woods, J. T. and Trantina, G. G. (1999). Material characterization for predicting impact performance of plastic parts. SAE Paper No. 1999-01-3178.

Download references


This work was supported by the Technology Innovation Program (Project ID: 20018493) funded by the Ministry of Trade, Industry & Energy (MOTIE, Korea).

Author information

Authors and Affiliations


Corresponding author

Correspondence to Byung Chul Kim.

Additional information

Publisher’s Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and Permissions

About this article

Verify currency and authenticity via CrossMark

Cite this article

Park, D.K., Kong, B.S. & Kim, B.C. Development of Crash Pad Using Overmolding Technology. Int.J Automot. Technol. 23, 1739–1745 (2022).

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI:

Key Words

  • Overmolding
  • PAB
  • Airbag deployment
  • Head impact performance
  • TPO