Instrument Panels

The main casing for instrument panels is usually made out of acrylonitrile-butadiene-styrene (ABS) / polycarbonate (PC) resins. Trim pieces in the panel are usually made out of polypropylene (PP).

The introduction of airbags into instrument panel design caused problems because of the strong structural support needed in the dash when the airbag inflates. This support can only currently be achieved by using steel reinforced beams that add weight and make the instrument panels more expensive. Also, instrument panels need to be redesigned because airbags are in the way of heating/cooling ducts that traditionally run the length of the dash. More intricate designs are needed to fit the increasing number of items in the front of the car.

Most instrument panels are currently being made by injection molding. But manufacturers are trying to design hollow, blow-molded, one or two piece systems that will have spaces for air ducts built right in. Problems with blow molding are that it is hard to fill out small spaces in an intricate mold that can be up to six feet long, and having small tolerances (meaning each dash must fall within a certain spec such as 6' 2" +/- 0.5 inches).

Metal and plastic pieces connected together