1. Tough economic conditions will force greater efforts to reduce cost and improve product effectiveness through accelerated design engineering. Value engineering processes took a back seat when business was booming. Now efforts will be redoubled to find more efficient assembly systems and more cost-effective materials.
2. Injection molding will gain more attention as a design tool, for plastics, metals and ceramics. Advances in materials, simulation and processing technology make injection molding more feasible for difficult (e.g. high temperature) applications. There will be growing emphasis on molders who offer design support and advanced technology, as other molders fall by the wayside.
3. Weight reduction efforts in cars will get far more serious as OEMs such as General Motors finish materials engineering for electric cars, such as the Chevy Volt. The short-term winners will be known materials solutions (e.g., forged aluminum wheels) rather than exotic and very expensive solutions (e.g., large scale use of carbon fiber composites).
4. Medical engineering will rise in importance as OEMs continue to move away from low-margin manufacturing. The troubles in the car industry received huge press in 2008, but this is a trend established more than 20 years ago.
5. The Japanese companies will lead in new engineering applications for plastics using natural feedstocks in place of hydrocarbons. Sixty per cent of the interior components of Toyota’s new hybrid will be made from plant-based plastics. Parts include scuff plates, headliners, and seat cushions.
A new compression molding compound material combines the light weight, strength, and rigidity of carbon fibers with the flexibility and lower cost of glass materials in a composite compatible with automotive production.
Plastic bearings are real and millions of them are in use doing heavy-duty jobs we used to think only metals could do. Some of Germany-based igus's bearings are traveling around the world as functional parts in a car to demonstrate what they can do.
Baxter showed off his 2.0-derived moves at ATX West this year. The big red guy still looks pretty much the same, but has some new abilities, mostly due to software. The research robot version is now being used in corporate R&D departments as a design platform.
End-production using 3D printing, including objects made of multiple materials in one pass, is getting closer to reality as we saw on the exhibit floor at the recent Pacific Design & Manufacturing Show.