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. The first is terawatt-scale battery production. Cell design. What does this mean for future products?

2020 97

GM boosting face mask production; sharing mask manufacturing plans

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Based on the number of requests for face masks for frontline workers, GM is increasing its production capacity for face masks at its Warren, Michigan facility. 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.

2020 101

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Volkswagen using AR to design new production lines in Chattanooga

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As the Volkswagen Chattanooga factory ramps up production of the new Atlas Cross Sport, and lays groundwork for assembling the next generation of Volkswagen electric vehicles planned to begin in 2022, engineers are using augmented reality (AR) goggles to design production lines and help spot potential issues. Different colors indicate the virtual position of new machinery along the Chattanooga production line. HMI Manufacturing Market Background

2020 85

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

Mitsubishi Heavy invests in Monolith Materials to support clean hydrogen production

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to support its commercial-scale, emissions-free hydrogen manufacturing technology. Monolith Materials is the first US manufacturer to produce “turquoise hydrogen” on a commercial scale. Hydrogen Hydrogen Production Natural GasMonolith Materials, Inc.

2020 136

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 OMP is an open industrial IoT platform to accelerate production and logistics optimization efforts. 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.

2020 73

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

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. Total/Saft will contribute its expertise in R&D and industrialization, and Groupe PSA its knowledge of the automotive market and its experience in production. At the end of this R&D phase, mass production could be launched in two “gigafactories”, in Douvrin (France) and Kaiserslautern (Germany).

2020 95

SEAT manufacturing automated ventilators with adapted windshield wiper motors

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—Nicolás Mora from the Production area of SEAT Martorell. 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. Health Manufacturing Market Background Vehicle Manufacturers

2020 85

BMW Group opens Competence Center for E-Drive Production in Dingolfing and expands manufacturing capacity

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The BMW Group has opened the Competence Center for E-Drive Production at its largest European manufacturing location in Dingolfing. Production of the highly integrated BMW e-drive—final assembly. Bavarian Minister-President Markus Söder and Chairman of the Board of Management of BMW AG Oliver Zipse symbolically launched production of the new, highly integrated BMW e-drive, which combines the electric motor, transmission and power electronics in a central housing.

2020 78

Ricardo awarded funding to develop digital-twin design and optimization for electrified powertrains

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As automakers seek to use digital engineering to speed-up development and improve real-world product quality and efficiency in electric and hybrid vehicles, Ricardo has been awarded £113,000 (US$150,000) in funding from the Office for Low Emission Vehicles (OLEV)—delivered through Innovate UK —to develop digital-twin-based design and optimization solutions for electrified powertrains. The use of digital twins as part of a virtual product development process.

2020 65

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. Daimler contributed its experience in large-scale production to the project.

2019 79

Škoda starts series production of MEB-based all-electric Enyaq

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ŠKODA AUTO has begun series production of the electric ENYAQ iV at its main plant in Mladá Boleslav. The battery-electric SUV is the first ŠKODA series production model based on the Volkswagen Group’s Modular Electrification Toolkit (MEB). The ENYAQ iV is ŠKODA’s first series-production model that was designed as an all-electric vehicle from the outset. —Michael Oeljeklaus, ŠKODA AUTO Board Member for Production and Logistics.

2020 86

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

Airbus and LM Industries create mobility startup Neorizon; digital manufacturing

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Airbus and LM Industries, the the parent company of Local Motors and Launch Forth, have formed Neorizon to provide disruptive and innovative products with an initial focus on local mobility and autonomy. The Neorizon microfactory is intended to build products at unprecedented speeds through the combination of co-creation and cutting-edge technology. Its efficiency will allow products to be iterated regularly to match customers’ needs and preferences.

2019 96

REE partners with Iochpe-Maxion on exclusive wheel and chassis designs for modular EV platform

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The REE platform provides customers full design freedom to create the broadest range of EV and autonomous vehicles.

2020 85

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

LEVC starts production of electric van VN5

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LEVC (London Electric Vehicle Company) has started production of its new electric van, VN5. The new model is designed, engineered and manufactured at LEVC’s plant in Ansty, Coventry—the UK’s only dedicated electric vehicle factory.

2020 132

SEAT large SUV Tarraco e-HYBRID PHEV enters production

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SEAT continues to expand its range of electrified vehicles, as the SEAT Tarraco e-HYBRID enters production this week. Hybrids Plug-ins Vehicle Manufacturers

2020 85

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

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

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 contract will provide a secure source of supply of battery cells for Mercedes-Benz’s electrification strategy, while Farasis gains security for its planned construction of production capacity. The East German site is designed as a CO 2 -neutral factory from the start. Batteries Manufacturing Vehicle Manufacturers

2020 71

BMW investing €400M in new vehicle assembly at Munich plant as part of shift to electromobility; engine production being concentrated at Steyr and Hams Hall

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The BMW Group is speeding up the shift towards electromobility and strengthening its global network for production of electrified vehicles. The new assembly in Munich will be built on the site currently used for engine production. Sustainability in production.

2020 108

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. —Udo Hänle, Head of Production Integration and Pilot Plant. Much of the work carried out there will focus on parts manufacturing for prototype construction, series production and customised solutions. 3D printing Manufacturing

2018 81

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. Arrano test and production engines will feature fuel injector nozzles made using Selective Laser Melting (SLM) techniques. This process will also be used to manufacture Ardiden 3 combustor swirlers.

2015 100

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. Hydrothermal Production of Single Crystal Ni-rich Cathodes with Extreme Rate Capability. Continuous high yield production of defect-free, ultrathin sulfide glass electrolytes for next generation solid state lithium metal batteries. Scale-up Production of Graphene Monoxide for Next-Generation LIB Anodes.

2020 71

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 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

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

Nuvera expands product line with new E-60 fuel cell system

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Building on the design of the E-45 engine released earlier this year, the E-60 model provides 59 kW net output power (67 kW gross power) to help OEMs meet increasing vehicle performance demands and market requirements, broadening the range of applications that can benefit from fuel cell power.

2020 130

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

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 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

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). Production of this PAPR starts today at Ford’s Vreeland facility near Flat Rock, Mich., In addition to the current production of more than 3 million face shields in Plymouth, Mich., Ford also is now producing face masks and leading an effort to scale production of reusable gowns for health care workers. Face mask production. Gown production.

2020 71

Conversion of Volkswagen Emden plant for EV production underway

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Volkswagen has begun conversion of its Emden, Germany plant to support the production of Evs; the first electric cars are to roll off the production line there from 2022. With the conversion of our plant at Emden into a production location for electric vehicles, Volkswagen is forcing the pace of system change. is to start production there in 2022 and will be followed by other all-electric models later. We are converting a major automobile plant during production.

2020 99

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

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

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. Batteries Europe Manufacturing Recycling

2020 65

Teijin joins AZL Partner Network for Lightweight Production Technology

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The network is launching one of their many joint projects today—an eight-month project to develop and manufacture multi-material battery enclosures for electric vehicles. Manufacturing Materials Weight reduction

2020 85

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

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

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