Siemens reports successful full load tests of additively manufactured CM247 gas turbine blades

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Siemens has achieved a breakthrough by finishing its first full load engine tests for gas turbine blades completely produced using Additive Manufacturing (AM) technology. The project team used blades manufactured at its 3D printing facility at Materials Solutions , in Worcester, UK.

2017 46

GM and Honda to establish industry-first $85M joint fuel cell system manufacturing operation in Michigan

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General Motors and Honda are establishing the auto industry’s first manufacturing joint venture—Fuel Cell System Manufacturing, LLC, FCSM)—to mass-produce an advanced hydrogen fuel cell system that will be used in future products from each company.

2017 36

Trending Sources

Millbrook designated RDE testing provider for type approval

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In the UK, Millbrook Group, the leading independent vehicle testing and validation services provider, is designated to provide real driving emissions (RDE) testing on behalf of Dutch approval authority, RDW.

2017 26

Stratasys demonstrates next-gen 3D printing for aerospace and automotive manufacturing; partnering with Ford

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the 3D printing and additive manufacturing solutions company, will preview demonstrations of next-generation manufacturing technologies at IMTS 2016 (International Manufacturing Technology Show, 12-17 September) as part of its SHAPING WHAT’S NEXT vision for manufacturing.

2016 32

NREL/Oak Ridge thermal measurements of packed copper wire enables better electric motor designs

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Improved thermal management of windings in electric motors makes it possible to maximize operational efficiency and longevity and reduce component footprint, allowing manufacturers to meet consumer demands for high-performance, reliable, and long-lasting EDVs. This ongoing study will help manufacturers and researchers design high-performance, long-lasting motors for EDVs.

2017 32

Iowa State to manage biorefinery projects for new Manufacturing USA Institute

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Iowa State University will bring its expertise in biorenewable technologies and pilot plant operations to the country’s 10th Manufacturing USA Institute. The recently announced advanced manufacturing institute is dedicated to improving the productivity and efficiency of chemical manufacturing. Such process intensification could boost manufacturing productivity while cutting costs and reducing waste.

Iowa 35

Alcoa unveils major advance in aluminum manufacturing technology; new Micromill targeting future automotive aluminum products

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Alcoa has developed new manufacturing technology—the Micromill—that will produce what the company says is the most advanced aluminum sheet on the market. Manufacturing Materials Weight reduction

Koito and Quanergy collaborate to design automotive headlight concept with built–in solid-state LiDAR

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Koito Manufacturing Co., a leading provider of LiDAR sensors and smart sensing solutions, are collaborating to design an automotive headlight concept with built-in Quanergy S3 solid state LiDAR sensors ( earlier post ). the largest global maker of automotive headlights, and Quanergy Systems, Inc.,

2017 28

NIST awards $7.4M in grants for additive manufacturing research

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million to fund two research projects aimed at improving measurement and standards for the rapidly developing field of additive manufacturing (AM). Additive manufacturing, also known as 3D printing, is a group of new technologies that build up objects, usually by laying down many thin layers on top of each other. Additive manufacturing processes face a variety of hurdles that limit their utility for high-value products and applications. Manufacturing

Ducker survey finds aluminum expected to represent 16% of total vehicle weight by 2028; transition to a multi-material design

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This is consistent with the emerging trend of automakers transitioning to a multi-material vehicle (MMV) design approach, choosing aluminum for doors, hoods and trunk lids, body-in-white, bumpers and crash boxes. Fuel Efficiency Manufacturing Materials Weight reduction

2020 12

Turbomeca introduces additive manufacturing capability for production engine components

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After years of maturation and prototype testing, helicopter engine manufacturer Turbomeca (Safran) has entered serial production of parts using the latest additive manufacturing (3D printing) process at its Bordes facility in France.

2015 23

Caltech team uses computational topology optimization to design silicon anode structures for Li-ion batteries

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Researchers at Caltech have used computational topology optimization methods to design optimal multifunctional silicon anode structures for lithium-ion batteries. In order to utilize high capacity silicon as a new anode material, several important design requirements must therefore be met.

2016 24

Ballard signs $25M deal with Broad-Ocean for manufacture & sales of 30 and 85 kW fuel cell systems in China

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Under the deal, Broad-Ocean will manufacture fuel cell modules in three strategic regions in China, including Shanghai. In each of the three assembly operation locations, Broad-Ocean plans to engage with local governments as well as with bus and commercial vehicle OEMs for deployment of fuel cell buses and commercial vehicles incorporating Ballard-designed modules manufactured by Broad-Ocean.

2017 30

Toyota investing $1B in new TNGA plant in Mexico, realigning North American manufacturing; expansion in Guangzhou

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Toyota is embarking on a multi-year plan to realign its manufacturing operations in North America in support of the Toyota New Global Architecture (TNGA) ( earlier post ), a comprehensive approach to achieving sustainable growth by making ever-better vehicles more efficiently. As part of this strategy, Toyota will invest approximately US$1 billion to construct its newest North American manufacturing facility in the state of Guanajuato in Central Mexico to produce the Corolla.

CMU/MIT study finds large-scale battery manufacturing will do little to reduce unit costs past a 200-300 MWh annual production level

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We investigate the role of battery design variables on the cost and performance of Li-ion batteries by first characterizing the tradeoffs in battery design and subsequently using this knowledge to optimize and assess technical and economic implications. electrode designs (e.g.:

Argonne VERIFI team improves code to enable up to 10K simultaneous engine simulations; paradigm shift in engine design

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These simulations are typical “engineering-type” smaller scale simulations, which are used routinely for engine design within industry. This massive simulation capacity has opened up a new capability for industrial partners seeking new advanced engine designs. Presently, engineers exploring new engine designs can do a small number of simulations—perhaps 100—on cluster computers, which can take weeks to complete.

2016 33

Dassault Systèmes and Airbus Group extend collaboration to additive manufacturing

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Dassault Systèmes announced that Airbus Group, after a two-year comprehensive benchmarking process, is extending its use of Dassault Systèmes’ 3DEXPERIENCE platform to its additive manufacturing programs integrating design, simulation and production. This provides Airbus Group with digital continuity to optimize its conceptual designs by virtually validating each phase of the additive manufacturing process.

Ontario seeking design concepts for hydrogen-powered regional rail trains

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The Canadian province of Ontario is electrifying its GO rail network to transform how people move around the Greater Toronto and Hamilton Area (GTHA), and is seeking design concepts for hydrogen-powered trains as an alternative to conventional overhead wires. A number of rail vehicle manufacturers will be commissioned to prepare designs and to demonstrate the impact that incorporating hydrogen fuel cells into bi-level trains would have on the performance of the GO rail network.

Pi Innovo and GaN Systems collaborate to offer electronics design services for auxiliary systems for multi-voltage, hybrid and electric vehicles

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Controls engineering firm Pi Innovo and gallium nitride (GaN) semiconductor manufacturer GaN Systems are collaborating to offer automakers a pathway to the efficient and effective electrification of auxiliary systems for multi-voltage conventional, hybrid-electric, and pure electric vehicles.

2016 31

New 7th-generation Hyundai Sonata updates design, tweaks powertrain

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design language, stiffer body structure, better ride quality, reduced noise, vibration and harshness and advanced safety and convenience features. Theta II featured numerous design enhancements over its predecessor, beginning with a three-stage variable induction system (VIS) which automatically adjusted the volume of the air sucked into the combustion chamber to create an air-to-fuel mix optimized for varying engine load conditions. 2015 Sonata 2.0T Click to enlarge.

2015 18

Car Manufacturer Spotlight: Renault

Green Cars News

In recent weeks it has released the final designs of its zero emission [.]. Where we stand: May 2010 Through its Alliance with Nissan, French automaker Renault has been one of the leaders in the production of zero emission electric vehicles and has plans to mass market a range of electric cars from 2011 onwards (see article).

Green 19

SMDI design study produces twist beam concept that reduces mass ~30% relative to baseline assembly

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mass reduction relative to the baseline assembly, at a 12–15% premium in manufacturing cost at production volumes of 30,000 to 250,000 vehicles per year, respectively. An S-Beam Design based on 22MnB5 sheet, DP780 tube and HSLA550 materials was predicted to have a 14.9%

Fuel 12

Quirky Danish electric car design wins Frost & Sullivan award

Green Cars News

The Danish manufacturer behind the design has been awarded the sought-after ‘2012 European Electric Vehicles Early Stage Investment Opportunity Award’ from internationally renown research firm Frost & Sullivan. Electric car maker ECOmove has won a prestigious award for its QBEAK electric vehicle concept, which is planned for production from 2013.

2013 24

New manufacturing technologies deliver lighter and stiffer 2014 Corvette

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Approximately $52 million of the investment went to a new body shop that manufactures the car’s all-new, lightweight aluminum frame in-house for the first time. Fuel Efficiency Manufacturing Weight reduction Aluminum resistance spot welding in Bowling Green.

Fuel 12

Shell Project M Concept City Car: Huge Efficiency Gains Possible, Designer Gordon Murray Says

Green Car Reports

Famed car designer Gordon Murray will team up with former Honda engine specialist Osamu Goto and oil company Shell to develop a concept for "an ultra-compact, efficient car for city use based around the internal combustion engine." Manufacturing minicar City car Gordon Murray concept Fuel Economy Shell T25

Honda 13

BMW lays cornerstone for new Lightweight Design Center at Landshut

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BMW held a cornerstone-laying ceremony for its new Lightweight Design Center at BMW’s Landshut site. Some 160 engineers will research innovative materials and manufacturing processes for future vehicle, starting at the end of 2016. BMW is investing about €20 million (US$22 million) in the center. Lightweight construction is one of the key technologies of the global automotive industry and a key differentiating feature in competition.

DOE awards $3.9M to 13 projects using high performance computing in manufacturing; Ford, LanzaTech

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million for 13 projects designed to stimulate the use of high performance supercomputing in US manufacturing. The Office of Energy Efficiency and Renewable Energy (EERE) Advanced Manufacturing Office’s High Performance Computing for Manufacturing (HPC4Mfg) program enables innovation in US manufacturing through the adoption of high performance computing (HPC) to advance applied science and technology relevant to manufacturing.

NIST, partners create new international standard to improve sustainable manufacturing

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A public-private team led by the National Institute of Standards and Technology (NIST) has created a new international standard that can “map” the critically important environmental aspects of manufacturing processes, leading to significant improvements in sustainability while keeping a product’s life cycle low cost and efficient. Manufacturers, as well as software suppliers that provide analysis and modeling solutions, will be the primary users of the new standard.

XL Hybrids partners with Knapheide Manufacturing to expand hybrid electric powertrain availability

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developer of a low-cost hybrid electric powertrain designed for class 1 to 3 commercial fleet vehicles ( earlier post ), has an agreement with The Knapheide Manufacturing Company, a commercial vehicle equipment provider in North America, for the installation and distribution of its products. The Knapheide Manufacturing Company is a leading US manufacturer and provider of commercial vehicle solutions. XL Hybrids, Inc.,

GMC 20

DOE to award up to $70M for Manufacturing Institute focused on reuse, recycling and remanufacturing

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The manufacturing sector, a subset of the industrial sector, consumes 24 quads of primary energy annually in the United States—about one quarter of total US energy use and roughly three-quarters of total industrial energy use. Manufacturing Sustainability

New Silexica SLX Automotive design tools feature Infineon TriCore models

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Silexica , a provider of multicore software design automation addressing complex, multicore platforms, released of its new SLX Automotive Development package, which provides programming support for multicore automotive software. In January 2017, Silexica joined the Automotive Open System Architecture (AUTOSAR), a worldwide development partnership of vehicle manufacturers, suppliers and other companies from the electronics, semiconductor and software industry.

What’s the next niche in car design?

Green Cars News

There are no longer boundaries in car design. Where once we had clearly defined sectors, and manufacturers stuck to them so we all knew what we were g

DOE announces $70M for Innovation Institute on Smart Manufacturing; advanced sensors, controls, platforms, and modeling for manufacturing

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The US Department of Energy announced up to $70 million in funding ( DE-FOA-0001263 ) for the next Clean Energy Manufacturing Innovation Institute, which will be focused on smart manufacturing. With this investment, the DOE aims to support research and development advancements that can reduce the cost of deployment for technologies such as advanced sensors, controls, platforms, and modeling for manufacturing by as much as 50%. Internet of Things Manufacturing Sensors

President Obama launches $500M Advanced Manufacturing Partnership; Ford involved as an initial partner

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US President Barack Obama today launched the Advanced Manufacturing Partnership (AMP), a national effort bringing together industry, universities, and the federal government to invest in emerging technologies such as information technology, biotechnology, and nanotechnology. The AMP is being developed based on the recommendation of the President’s Council of Advisors on Science and Technology (PCAST), which today released a report entitled “Ensuring Leadership in Advanced Manufacturing.”

Kokam introduces new XPAND Li-ion pack for electric vehicle manufacturers; advanced liquid cooling, 150 Wh/kg

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Ltd, has introduced the XPAND battery pack, delivering electric vehicle manufacturers a safe, high-performance, cost-effective battery solution for electric bus, tram, truck, ground support equipment (GSE), military, marine, special-purpose and other commercial and industrial electric vehicle (EV) applications. Kokam Co.,

Detroit Electric SP:01 Sports Car: Final Design Announced

Green Car Reports

Even when the new company shares its name with one of the original manufacturers of electric cars. Starting a new company is always somewhat difficult, but that’s particularly true in the car business. ALSO SEE: Detroit Electric SP:01 - The New Tesla Roadster? The first prototype of the Detroit Electric SP:01 electric sports car was shown in

Tesla 12

Graphene ultracap manufacturer Skeleton Technologies receives €13M investment; Series C led by FirstFloor Capital

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European ultracapacitor manufacturer Skeleton Technologies has received €13 million (US$14.5 Skeleton Technologies’ devices are the only ultracapacitors to use a patented graphene-based material in their manufacture, allowing them to deliver twice the energy density and five times the power density of their competitors. million) in new investment led by FirstFloor Capital, a Malaysian venture capital investment firm specializing in funding high-growth technology companies.

Elio Motors releases body framing and engine cradle design to suppliers for E-Series engineering prototype builds

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Elio Motors, the startup vehicle manufacturer launching a three-wheeled vehicle that will get up to 84 MPG with a targeted base price of $6,800 ( earlier post ), has released to its suppliers the body framing and engine cradle design for its E-Series engineering prototypes. The E-Series prototypes will be used for safety, wind tunnel and manufacturability validation, prior to the start of commercial production.

Westport to begin delivering HPDI 2.0 early production-design-intent components to OEMs in Q1 2016

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announced that early production-design-intent components in the Westport High Pressure Direct Injection (Westport HPDI) second-generation (HPDI 2.0) Manufacturing systems engineering and initial equipment orders for this production facility are now well underway. For heavy-duty vehicle manufacturers, minimal change to the base diesel engine means simpler integration into engine and vehicle production. Westport Innovations Inc.

Manufacturing Spotlight: Vauxhall

Green Cars News

Its vehicles are largely identical to those of the Opel brand, which is sold across Europe, with most designed in Germany and produced across Germany, Spain and Poland, [.]. Vauxhall ecoFLEX Manufacturer Spotlight Vauxhall AmperaWhere we stand: May, 2012 The Vauxhall brand of General Motors has been the second largest selling motoring brand in the UK for more than two decades.