Abstract
A large-sized, one-piece, blow molded bumper was developed for Isuzu's 4-ton truck. This low weight bumper was developed using a new blend polypropylene-based material which gives uniform, defect-free flat surfaces. Along with it's low tooling cost, the double action blow molding process used yields a much better outer surface with uniform thickness. At the same time, a more complex inner surface for structural purposes is also possible. In addition, this new material does not require trichloroethane (TCE) pre-treatment prior to painting. We believe that this development process points out the outstanding potential in the use of blow molding for the manufacture of other complex plastic parts.