Tesla seeking 56% cut in $/kWh, $25K EV in three years through manufacturing and design innovations

Green Car Congress

The baseline precept for the presentation was the centrality and associated difficulty of manufacturing new technologies at a scale sufficient to make a tangible difference. Cell design. The aim of Tesla is to be the best in manufacturing of any company on earth.

2020 97

GM to lead design, development and manufacturing of own family of next-generation EV drive units and motors: Ultium Drive

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General Motors announced that it will design, develop and manufacture a family of five interchangeable electric drive units and three motors, known collectively as “Ultium Drive.”

2020 85

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GM boosting face mask production; sharing mask manufacturing plans

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In addition, the company has shared its manufacturing plans with GM suppliers along with the Original Equipment Suppliers Association and the Michigan Manufacturers Association ( MMA ) to help other manufacturers ramp up their own production efforts. The Michigan Manufacturers Association has 1,700 companies across all industries, and many are looking for ways to help during this crisis,” said John Walsh, Michigan Manufacturers Association president and CEO. “GM’s

2020 101

ZF joins Open Manufacturing Platform

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ZF Friedrichshafen AG is joining the Open Manufacturing Platform (OMP), which was announced in 2019 by the BMW Group and Microsoft. The aim of this initiative is to enable faster and more cost-effective innovations in the manufacturing industry. The OMP technology framework and community are designed to nurture the development of smart-factory solutions across the sector. Internet of Things Manufacturing

2020 73

PSA and Total create JV for manufacture of EV batteries in Europe; €5B investment

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With this partnership, the parties are setting up a world-class player in the development and manufacture of high-performance batteries for the automotive industry from 2023. Ensure industrial independence in Europe for the conception and manufacture of batteries, with an initial capacity of 8 GWh, reaching a cumulative capacity of 48 GWh on both sites by 2030. Position ACC as a major competitive player in supplying electric vehicle manufacturers.

2020 95

CARB warns vehicle and engine manufacturers about hiding software or hardware changes that affect emissions

Green Car Congress

The California Air Resources Board (CARB) sent a letter to automakers and other vehicle and engine manufacturers encouraging them to disclose by the end of the year any unapproved hardware or software programs that impact emissions control systems in vehicles sold in California. Since then, CARB has found similar issues with other manufacturers as part of its ongoing enforcement efforts. Emissions Engines Regulations Vehicle Manufacturers

2020 69

SEAT manufacturing automated ventilators with adapted windshield wiper motors

Green Car Congress

A team of engineers diligently set about designing several prototypes—13 in all—until the definitive model was produced. Designed in collaboration with Protofy.XYZ, they are being assembled at the SEAT facilities. Taking an assembly line that manufactures subframes, a car part, and adapting it to make ventilators has been a lengthy, difficult job involving many areas of the company, and we managed to do it in the record time of one week.

2020 85

Team at Naval Research Laboratory suggests design direction for structural batteries

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Structural batteries, i.e., batteries designed to bear mechanical loads, are projected to substantially increase system-level specific energy, resulting in electric vehicles with 70% more range and unmanned aerial vehicles (UAVs) with 41% longer hovering times.

2020 90

Airbus and LM Industries create mobility startup Neorizon; digital manufacturing

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Current transport infrastructure and existing mass manufacturing are too inflexible and capital intense to service evolving technology trends and changing consumer demands. Neorizon brings together the flexibility of professional digital manufacturing and the expertise of one of the world’s leading aerospace and defense companies. 3D printing Manufacturing Mobility Mobility services

2019 96

XPeng enters into cooperation agreement for new smart EV manufacturing base in Guangzhou; $586M in financing

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According to the terms of the Cooperation Agreement, Guangzhou GET Investment agrees to provide RMB 4 billion (US$586 million) in financing to help fuel XPeng’s growth as well as support the construction of a new smart EV manufacturing base for XPeng in the Guangzhou Economic and Technological Development Zone. billion (US$191 million) to construct the smart EV manufacturing base according to design requirements and specifications to be provided by Guangdong Xiaopeng.

2020 65

BMW Group and Microsoft launch Open Manufacturing Platform

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At Hannover Messe, Microsoft and the BMW Group announced a new community initiative to enable faster, more cost-effective innovation in the manufacturing sector. Manufacturing production and profitability can be hindered by complex, proprietary systems that create data silos and slow productivity. The Open Manufacturing Platform (OMP) is designed to break down these barriers through the creation of an open technology framework and cross-industry community.

2019 101

Argonne using machine learning to optimize designing and manufacturing of new products; HD engine simulation presented at WCX

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Researchers at the US Department of Energy’s (DOE) Argonne National Laboratory are developing advanced machine learning techniques with high-performance computing (HPC) to help organizations reduce design time from months to days and slash development costs. This technology can be applied to manufacturing to quickly find the best design for a product or the most efficient production process. High Performance Computing Manufacturing Simulation

2018 69

DOE awards $1.95M for conceptual designs that extract critical minerals and rare earth elements from coal sources

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million in federal funding to develop conceptual designs of commercially viable technologies that will extract rare earth elements (REEs) from US coal and coal by-product sources. The conceptual designs will include system configurations, equipment features, performance characteristics, and associated costs for systems that produce at least 1–3 metric tons per day of mixed rare earth oxides (REOs) or rare earth salts (RESs) and other critical minerals (CMs) in some designs.

2020 65

OXIS Energy to build Li-S manufacturing plant in Brazil

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OXIS Energy and the Minas Gerais Development Company CODEMGE have signed a 15-year lease agreement with Mercedes Benz Brazil (MBB) to take possession of a plant located at the MBB manufacturing site in Juiz de Fora in southeast Brazil to build a Li-sulfur battery manufacturing operation. NORDIKA Pharmaceutical of Brazil will undertake the design and engineering associated with the plant and machinery layout. Batteries Brazil Li-Sulfur Manufacturing

2020 69

DOE’s Manufacturing Institute to award $35M to support R&D in recycling, reuse and remanufacturing

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The US Department of Energy’s (DOE’s) Reducing EMbodied-Energy and Decreasing Emissions (REMADE) Manufacturing Institute announced approximately $35 million to support research and development (R&D) that will enable US manufacturers to increase the recovery, recycling, reuse, and remanufacturing of plastics, metals, electronic waste, and fibers. Design Iteration Tool to Sustain Remanufacturability. Manufacturing Market Background Recycling

2020 75

DOE selects national laboratories to establish industry partnerships for battery manufacturing innovation

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The US Department of Energy (DOE) selected 13 projects through a Battery Manufacturing Lab Call with combined funding of almost $15 million over three years. High-throughput Laser Processing and Acoustic Diagnostics for Enhanced Battery Performance and Manufacturing. High-Energy and High-Power NMP-Free Designer Electrodes with Ultra-thick Architectures Processed by Multilayer Slot-Die Coating and Electrophoretic Deposition. Batteries Manufacturing Market Background

2020 71

Mercedes-Benz announces strategic partnership and equity stake in Chinese battery cell manufacturer Farasis

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Mercedes-Benz has entered a far-reaching strategic partnership with the Chinese battery cell manufacturer Farasis Energy (Ganzhou) Co., The East German site is designed as a CO 2 -neutral factory from the start. The stake will give Daimler the option to nominate a representative for a seat on the supervisory board of the battery cell manufacturer. Batteries Manufacturing Vehicle Manufacturers

2020 71

Honda R&D partners with Autodesk to use AM and generative design to reduce weight of crankshaft

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To achieve a reductive design, the structure and materials used in every part must be scrutinized. Over the long history of engine development, the crankshaft design had become a foregone conclusion. Despite this, we set the challenging goal of designing a crankshaft to be 30% lighter than current models. —Hirosumi Todaka, a mechanical and fluid machinery designer at Honda R&D’s advanced technology lab. The team continued its work and designed a second-lot model.

2020 75

BMW Group plans Additive Manufacturing Campus

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The BMW Group will invest more than €10 million in a new Additive Manufacturing Campus. Our new Additive Manufacturing Campus will concentrate the full spectrum of the BMW Group’s 3D printing expertise at a single location. Within the BMW Group production network, the new Additive Manufacturing Campus will foster the latest technologies in this field in much the same way as a pilot plant and make them available for use within the network. 3D printing Manufacturing

2018 81

DOE selects 11 manufacturing and materials projects to receive $3.3M for high performance computing research

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The projects will use high performance computing to address key technical challenges in US manufacturing and materials development. Through DOE’s High Performance Computing for Energy Innovation (HPC4EI) initiative, selected teams will work with the Department’s National Laboratories to apply advanced modeling, simulation, and data analysis for projects that improve manufacturing productivity and explore materials that can withstand extreme conditions.

2020 80

Battery manufacturer Northvolt raises $600M to invest in capacity expansion, R&D and giga-scale recycling; Volkswagen kicks in more

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European battery maker Northvolt signed a $600-million private placement, led by Baillie Gifford, Goldman Sachs Merchant Banking Division and Volkswagen AG, enabling the company to make further investments in expanding its production and recycling capacity as well as R&D activities to support the target of establishing 150 GWh of manufacturing capacity in Europe by 2030. Northvolt Zwei takes its design from the Northvolt blueprint for battery manufacturing developed for Northvolt Ett.

2020 65

DOE to award $89M for innovative manufacturing technologies

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US Energy Secretary Rick Perry announced $89 million to support innovative, advanced manufacturing research and development projects ( DE-FOA-0001980 ). This Department of Energy (DOE) Funding Opportunity Announcement (FOA) tackles key priorities such as domestic manufacturing for energy storage. US manufacturers have created almost 500,000 jobs since 2017 and more than 250,000 jobs in the last year alone. The manufacturing sector also uses 25% of the nation’s energy.

2019 75

Lightning Systems more than tripling size of manufacturing and R&D facility in Colorado

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With more than $32 million in pending orders from commercial and government fleets, commercial electric vehicle supplier Lightning Systems is more than tripling the size of its manufacturing, research and development facility in Loveland, Colorado. Lightning moved its headquarters, manufacturing, and R&D into the former Hewlett-Packard/Agilent campus in southwest Loveland three years ago. Conversions Electric (Battery) Manufacturing

2020 73

DOE announces $3M to improve manufacturing processes through high performance computing

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The US Department of Energy (DOE) announced up to $3 million for high-performance computing, modeling, and simulation projects to improve manufacturing processes. Applicants are highly encouraged to partner with universities and non-profit organizations located within federally designated Opportunity Zones and/or Historically Black Colleges and Universities (HBCUs). High Performance Computing Manufacturing

2020 78

Siemens and EDAG intensify cooperation on additive manufacturing for automotive

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Siemens is intensifying its cooperation with the EDAG Group —a leading global independent engineering company for the automotive industry—further to promote industrial applications of additive manufacturing (AM) and to make engineering and production processes more efficient. intelligent modular system features a combination of bionically designed and additive-manufactured nodes and high-strength, energy-absorbing aluminum extrusion profiles.

2019 78

DOE to fund national laboratories to establish industry partnerships for battery manufacturing innovation

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The US Department of Energy (DOE) is soliciting proposals from the National Laboratories and industry partners that pursue radical innovations for American battery manufacturing leadership. This funding opportunity is a part of the Energy Storage Grand Challenge, a DOE-wide effort to create and sustain global leadership in energy storage utilization and exports, with a secure domestic manufacturing supply chain that does not depend on foreign sources of critical materials.

2020 65

Mullen Technologies executes LOI for $135M in funding to acquire an existing EV manufacturing plant in the US

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a Southern California-based licensed electric vehicle manufacturer, executed an LOI with Axiom Financial for $135 million in funding to acquire and build out an electric vehicle manufacturing plant. At this time, Mullen is pre-approved for funding via non-recourse, asset-backed Line of Credit (“LOC”) totaling $135 million with Axiom Financial to be used for the purchase of the plant to manufacture Mullen Electric vehicles. Mullen Technologies Inc.,

2020 65

GM using Autodesk generative design software for lightweighting work

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GM is using new generative design software technology from Autodesk to support its vehicle lightweighting efforts. Generative design mimics nature’s evolutionary approach to design. Designers or engineers input design goals into generative design software, along with parameters such as such as weight, strength, material choice, fabrication method, and more. GM is utilizing the innovative technology on future product designs.

2018 75

Ford develops and begins manufacturing new powered respirator; expanding other COVID-19 efforts

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Ford, with design and testing consultation from 3M, has developed a new powered air-purifying respirator (PAPR). Ford has also started providing manufacturing expertise to help scientific instrument provider Thermo Fisher Scientific quickly expand production of COVID-19 collection kits to test for the virus. With this additional help, 3M and Ford were able to increase the output of PAPRs and N95 respirators at 3M’s US-based manufacturing facilities. Health Manufacturing

2020 71

Equipmake and HiETA developing new motor with 20kW/kg power density using additive manufacturing

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UK-based electrification company, Equipmake, has teamed up with additive manufacturing organization HiETA to develop a next-generation motor as part of a project grant-funded by Innovate UK. The key to AMPERE’s performance is its combination of an advanced motor design with additive manufacturing, allowing its metal structure to be 3D-printed, rather than milled from a solid billet.

2020 113

NIST: Blockchain provides security, traceability for smart manufacturing; digital thread

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According to a new National Institute of Standards and Technology (NIST) report, blockchain technology can not only provide tamper-proof transmission of manufacturing data, it also yields something just as valuable to its users—traceability of that data to all participants in the production process. Because blockchain gives us both capabilities, we can build trustworthiness into digital manufacturing networks. NIST Advanced Manufacturing Series 300-6 doi: 10.6028/NIST.AMS.300-6.

2019 75

New $3M round of funding for DOE High Performance Computing for Manufacturing

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The US Department of Energy (DOE) announced up to $3 million in funding to spur the use of US National Laboratory supercomputing resources to strengthen domestic manufacturing. Under DOE’s High Performance Computing for Energy Innovation (HPC4EI) solicitation, competitively-selected project teams will work with the labs to apply advanced modeling, simulation, and data analysis to achieve energy, material, and cost savings in manufacturing.

2020 69

For Greener Manufacturing, Think IAQ

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The next generation of cars will be cleaner and greener than ever—but a lot of the manufacturing processes that go into them are still pretty dirty. From the frame to the muffler, automotive manufacturing still involves welding, cutting, grinding and machining. Controlling toxic particulates from manufacturing processes is one of the most important things auto manufacturers can do to improve their sustainability and protect their workers.

2017 60

Volvo Technology Award for wave piston design

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The Volvo Group’s new truck engines are more fuel efficient as a result of their new piston design which adds waves to the piston crown to improve the use of oxygen. The new wave design has now been patented. It must be possible to manufacture any new design cost-effectively in order for it to be used in production vehicles. This was followed by thousands of hours of testing to refine the design and verify the durability of the new concept.

2017 88

ORNL, Lincoln Electric advance collaboration on large-scale metal additive manufacturing technology

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Oak Ridge National Laboratory and Lincoln Electric announced their continued collaboration on large-scale, robotic additive manufacturing technology at the Department of Energy’s Advanced Manufacturing InnovationXLab Summit. The new agreement builds upon ORNL and Lincoln Electric’s previous developments by extending additive technology to new materials, leveraging data analytics and enabling rapid manufacture of metal components in excess of 100 pounds per hour.

2019 81

ORNL, University of Toledo to collaborate on advanced materials, manufacturing research for vehicle applications

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The US Department of Energy’s Oak Ridge National Laboratory and The University of Toledo have entered into a memorandum of understanding for collaborative research into the advanced design and manufacturing of high-strength, intelligent, lightweight materials for use by the automotive sector. Manufacturing Materials Weight reduction

2019 71

HyperSolar working with Suzhou GH New Energy to accelerate manufacturing of renewable solar hydrogen panels

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a division of GCL Poly, in China to make the final modifications to the solar cells required to manufacture the Gen 1 hydrogen production panels to be used in demonstration pilot plants. The panel has a modular design that can be scaled up for a larger panel with the ability to change out individual cells. The pilot plant itself will be a full plug and play facility which will be initially designed with the Gen 1 technology. HyperSolar, Inc.,

2020 93

Stanford team proposes new design strategy for electrolytes for lithium metal batteries

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Stanford University scientists have proposed a design strategy for electrolytes that enable anode-free Li metal batteries with single-solvent single-salt formations at standard concentrations. Based on the results reported in a paper in the journal Nature Energy , the design concept provides a promising path to high-energy, long-cycling Li metal batteries, the researchers said.

2020 79

New auto consortium targets material challenges in design, simulation, lightweighting, global manufacturing, and emissions reduction

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At SAE World Congress in Detroit, Granta Design announced the launch of the Automotive Material Intelligence Consortium ( AutoMatIC ). Good materials data and effective materials decisions are essential in optimizing product designs for global manufacturing, lightweighting, and emissions reduction.

2014 78

GM China Tech Day 2013 showcased advanced manufacturing processes, technologies and designs

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This year’s event showcased developments in advanced manufacturing processes, user-friendly automotive technologies and advanced vehicle designs at the ATC. Here, engineers can rapidly produce prototypes of parts and at far lower cost than with traditional manufacturing. This helps them evaluate potential designs and make faster decisions, speeding new products to the market faster.

2013 78

“WaterBone” design wins grand prize in ARPA-E LITECAR Challenge

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The winning design: “WaterBone”. The design challenge served to accelerate innovative ideas by using novel material technologies, structural designs, energy absorbing materials and unique methods of manufacturing to reduce vehicle curb weight while maintaining current US automotive safety standards. 254 conceptual designs were submitted. The envelope’s material is a polymer composite, which provides desirable characteristics of a monocoque design.

2015 94

Daimler, partners building next-gen additive manufacturing process pilot production line for spare parts

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NextGenAM partners Premium AEROTEC, EOS and Daimler are building a pilot production line for a next-generation automated additive manufacturing (AM) process. The aim of the project is to develop a digitalized next-generation manufacturing line which can produce aluminum components for the automotive and aerospace sectors significantly more cost-effectively than is currently possible. 3D printing Manufacturing

2019 79

Audi and Ericsson to pioneer 5G for automotive manufacturing

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Ericsson is already running 5G industry programs all over the world to help manufacturers boost productivity and create new business opportunities. This project is a great opportunity to see what is possible when we bring 5G into an automobile production environment to truly enable smart wireless manufacturing. survey, the 2018 Manufacturing Global Expert Survey , found that two-thirds of manufacturing companies rank digitizing the production value chain (Industry 4.0)

2018 65