CVG designs, engineers and produces trim systems and components for commercial vehicle cab interiors. Our in-house expertise and state-of-the-art thermal and acoustic labs and tools lead to solutions that improve vehicle performance. They address issues such as idle reduction, while ensuring vehicle operator and occupant comfort. CVG’s products are attractive and include lightweight solutions from a traditional cut and sew approach to a contemporary “molded” styling theme. Parts can be color matched or top good wrapped to integrate seamlessly with the rest of the interior.
CVG’s variety of interior trim manufacturing processes provides nearly unlimited tooling, cost and design options to match program needs and brand image. Our expertise and capabilities include 3D processes such as injection molding, low pressure injection molding, urethane molding and foaming processes, compression molding, heavy-gauge thermoforming and vacuum forming. Various 2D processes include cutting, sewing, trimming and finishing methods.
From A-pillars, B-pillars, instrument panels and interior trim panels to flooring, sleeper bunks and storage systems, CVG has your interior covered.
CVG Trim Processes
CVG’s variety of trim processes and expertise provides the ultimate flexibility in cost, design, lead time and styling options. We can mix and match any combination of the following processes to suit your needs.
The Structural Rigid process uses steel or aluminum tools and is a high-density rigid system, molded at approximately 55pcf. This system produces parts with excellent strength and impact characteristics and is ideal for parts that require intricate detail and in-mold coating. Typical applications include medical and electronic housings, structural coverings and exterior covers and panels.
T-RIM™ Reaction Injection Molding
CVG’s T-RIM™ process provides increased flexural modulus as well as better dimensional and thermal stability, allowing thinner wall sections to be created while meeting structural performance requirements. These characteristics add up to enhanced product performance, additional space for backside features and show surface design freedom. This provides maximum internal space for panel loading, HVAC ducting, wiring, electronics, airbags and other components. T-RIM™ eliminates the added weight, material and labor costs of steel substructures commonly used to control expansion and contraction.
I-SKIN™ Integral Skin
To produce I-Skin™, CVG utilizes an elastomeric material to form a durable skin over a soft inner core. It is typically molded at 20-30pcf with steel, aluminum or epoxy tools. Custom colors can be molded with an in-mold coated paint and are offered in UV stable and low-density systems chemically bonded to the I-SKIN™ substrate to match other components.
Instrument panels, armrests, grab handles, bumper pads, soft interior trim and storage trays are a few examples of I-Skin™ substrate in order to match other components.
Instrument panels, armrests, grab handles, bumper pads, soft interior trim and storage trays are a few examples of I-Skin™ applications.
Vinyl Clad Rigid (VCR)
VCR is a low-density, closed-cell rigid urethane with a vinyl skin. It is a high quality process that has a proven history in the heavy duty truck and marine markets. It has a high degree of design flexibility as well as great weight-to-strength ratios. Vinyl can be matched to upholstery, color, grain and softness.
VCR is suitable for a variety of applications including consoles and dashes, custom marine dashes, cabinets, doors, drawers, sleeper control panels and work tables.
Micro Cellular Elastomeric Urethane (MCU)
Using MCU, CVG developed a high durability, lightweight bumper fascia capable of withstanding repeated impacts that would deform an aluminum or steel bumper. Even after repeated impacts, the appearance doesn’t suffer due to a paint layer that’s been chemically bonded to the part. The paint is added before the part is molded, ensuring superior adhesion to the fascia surface. Besides being durable, this bumper can replace several fabricated metal parts, reducing part count, associated cost and weight.
In addition to bumpers, MCU is ideal for parts exposed to harsh environments such as forklift instrument panels, industrial machinery instrument panels, fairings, fender covers and kick panels.
Injection Molding consists of a material introduced to a heated barrel with a rotating screw inside, which reduces the material into a melted state. This melt is forced into a multi-piece mold under pressure. After the part cures, the mold is opened and a finished part is removed. CVG’s gas assist molding capabilities are an option that helps lower costs by reducing molded product weight and plastic material, molding time cycles and in-mold pressures for less wear on the molds. Multi-cavity tooling can produce many similar parts in a single cycle.
CVG can provide secondary operations at the press where cycle time permits, providing additional value to our customers. Injection molded applications include door trim, structural components, A/B pillars, instrument panels, bezels, subcomponents such as grommets, clips, housings, hooks, etc.
Thermoforming produces parts similar in appearance to injection molding, blow molding, roto-molding and RIM. Parts can be smooth and glossy, have texture, or can be internally colored or painted. CVG’s Thermoforming process is ideal for large (up to 8’x5’x4’ in size) internal and external trim parts with low to medium volume and frequent revisions and/or short life cycles.
Sheet plastic is heated and then formed to the shape of a tool from either vacuum, pressure or both. Pressure forming processes can produce highly intricate A-side surfaces. After the hot plastic solidifies, its shape conforms to the mold. The part is trimmed to its final form by hand or machine.
CVG currently provides secondary operations including bonding, mechanical fastening, ultrasonic welding, painting, silk screening / pad printing and EMI / RFI shielding to meet customer needs.
Pressure Contour Bonding
Using non-metallic forming tools, sheets of pre-extruded materials are heated horizontally and formed utilizing compression forces and air pressure. Initially, the part is formed through compression forces (i.e., a mechanical press closing two tool halves together). Next, air pressure (inside the tool halves while heat is present) completes the forming and bonding of the part (setting the shape as heat dissipates). This pressurization provides a consistent surface pressure, allowing a uniform cross-sectional thickness of the materials and assuring a uniform bond. The part is then trimmed, either by hand or by machine, to obtain its final form. Both substrate and top good materials are formed in this one-step process.
CVG’s Pressure Contour Bonding process is ideal for trim panel, headliner, back wall and side panel applications.
CVG’s Compression Molding process is a highly flexible procedure, allowing a variety of substrates that can be selected to match the strength and shape requirements of the part. Compression Molding is well suited for highly contoured parts including headliners, interior panels, structural panels and door panels. Key advantages include:
• Ability to use a variety of top goods
• Produces a high-strength part
• Top goods are applied and bonded in mold
• High flexibility of tool design such as in-mold trimming
• Ability to produce hollow cross sections with blow assist and two sheets of substrate
CVG’s patented Trim 3D™ is a compression molding process that produces parts with molded contouring while optimizing packaging requirements, enhancing styling and offering a lightweight product. The Trim 3D™ process allows deep draw contouring with as much as 22 inches of variance in a plane.
The TRIM 2D™ process provides customers flexibility of product styling, including accent color inserts and bolsters in vinyl, fabric or a combination of both. CVG’s Trim 2D™ process provides a lightweight, cost-effective solution for parts that require very low tooling investment. Key advantages include:
- Full surface bond
- Inexpensive tooling: steel rule dies
- Quick tooling turnaround times
- Customizable designs
- Well suited for low volumes
- Ability to produce large parts
CVG offers refined Embroidery for all soft trim interior components. Embroidery can be tailored to customer-specific needs, providing a custom-made appearance. Various materials, including fabric and vinyl, can be utilized to accommodate your Embroidery requirements. CVG has nine-color capability for each embroidery design and can produce a wide range of sizes and shapes. Embroidery provides a higher class look to your interior trim components.
Cut and Sew
For customers who want products that are tailored with a custom-made appearance, CVG offers a refined handcrafted Cut and Sew process. Various fabrics, vinyls and other materials are cut to shape, usually on a CNC cutting table, and assembled using various methods including sewing and buttoning. The pieces are sewn into various cover and trim parts such as curtains, seat covers and interior trim panels to produce extremely plush, handcrafted, high quality parts.
CVG offers innovative FinishTEK™ commercial vehicle finishes that are durable and decorative. Customized applications feature interior and exterior finishes with industrial paint, UV hard coating and unique hydrographic film for designs on three-dimensional objects. FinishTEK™ provides full coverage coatings that are, among other benefits, scratch- and chemical-resistant.
CVG’s innovative FlameTEK™ is a self-extinguishing interior trim product suited for commercial, bus and other specialty vehicle use. The trim also provides notable additional benefits: enhanced thermal protection to improve HVAC operation and potentially save fuel; improved acoustical performance to reduce road noise; and operator environment trim that is antimicrobial and UV and chemical resistance. FlameTEK™ adapts to curved surfaces to fit several vehicle configurations.
CVG’s progressive efforts to combine ingenuity with safety and comfort for the benefit of operators result in innovative solutions such as our ComforTEKTM flooring for commercial freight trucks. ComforTEK™ provides thermal resistance to engine and exhaust heat that can reduce the cab flooring temperature by nearly 20 degrees. It also offers a significantly softer floor to stand on while working to reduce leg pain.