This paper will review the development and design of the DaimlerChrysler 4.7L V-8 engine. The new plastic cover module, comprised of a glass reinforced vinyl ester thermoset, was developed in just 12 months and replaces a magnesium component. Significant cost savings were
realized, while incrementally improving noise, vibration, and harshness (NVH). Extensive finite element analyses (FEA), including mold filling analysis and anistropic property calculation, were utilized to ensure robust system performance. This collaborative effort eliminated the prototype step for the cover housing, which in turn reduced development time and cost by allowing the component to move directly from design to production. This capability also allowed NVH improvement to be realized over the already favorable acoustical performance of the previous die-cast magnesium component.