One of the weirder materials developments from the economic slowdown is a shortage of sawdust. Prices are up some 25 percent in the past two years, if you can get it. Sawdust is not normally considered an engineering material, but it’s often used as an additive for plastic compounds that cover steering wheels and dashboards. Demand for wood plastic composites has grown dramatically and is close to a billion pounds this year, mostly for construction applications. Composites are typically close to half wood flour and high-density polyethylene, with a smattering of other additives such as stabilizers and pigments. Wood plastic composites are favored for automotive applications because they have a lower specific gravity than compounds made with other inorganic materials. They also give an “organic” look and are considered environmentally friendly. The new economics, however, surely will slow penetration. The reason is the slowdown in house construction, which is slowing timber operations. The weakness of the US dollar versus the Canadian dollar also is having an impact.
Siemens and Fraunhofer Institute for Laser Technology have achieved a faster production process based on selective laser melting for speeding up the prototyping of big, complex metal parts in gas turbine engines.
BMW has already incorporated more than 10,000 3D-printed parts in the Rolls-Royce Phantom and intends to expand the use of 3D printing in its cars even more in the future. Meanwhile, Daimler has started using additive manufacturing for producing spare parts in Mercedes-Benz Trucks.
SABIC's lightweighting polycarbonate glazing materials have appeared for the first time in a production car: the rear quarter window of Toyota's special edition 86 GRMN sports car, where they're saving 50% of its weight compared to conventional glass.
Design engineers play a big role in selecting both suppliers and materials for their designs. Our most recent Design News Materials Survey says they continue to be highly involved, in some ways even more than the last time we asked to peek inside their cubicles.
Daihatsu is one of the first carmakers to customize car exteriors using 3D printing's mass customization capabilities. Effect Skins -- small exterior bumper and fender panels in different colors and textures -- can be ordered for its Copen convertible.
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