Considering a move to bioplastics? Consider the experience of John Deere, which is now in the eighth year of a program to use soybean and corn feedstocks that was not originally driven for green reasons. The biomaterials are used in combine panels, backhoe loader hoods, and tractor hoods. Greg McCunnn, who runs the project, says the materials must be cost competitive and must be a performance drop-in for petroleum-based plastics. Needless to say, significant supply chain work was involved, and included funding from the United Soybean Board. Ashland Specialty Chemicals developed polyester resins that include soy and corn feedstocks, while processors Ashley Industrial Molding and Budd (currently Continental Structural Plastics) worked on the molding side. There were also issues related to painting and mold release.
And it amounts to more than a hill of beans: each combine made with the compound uses 1.1 bushels of soybeans and 0.5 bushels of corn.
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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