Abstract
DAIHATSU has developed a plastic intake manifold with a new design concept and new manufacturing process. To get maximum cost effectiveness, we have developed the engine to be optimized. Moreover we have adopted the "DRI(Die Rotary Injection)" process in cooperation with DAIKYO. The "DRI" process has brought the biggest cost advantage compared with a fusible core process or vibration welding. We have also confirmed that the "DRI" process produces quality parts suitable for an intake manifold. Cost reduction as much as 60% compared with aluminum manifold was achieved while maintaining performance and quality requirements.