Highly porous carbon foam structures bonded with polymers such as polypropylene replace lead plates in typical vehicle batteries in a novel materials’ solution to problems with battery life and weight. The innovation comes from a company called Firefly Energy, using technology developed in the R&D Labs at Caterpillar, which was looking for a better battery for its vehicles. In the invention, carbon-graphite foam “grids” are loaded with lead oxides. The foam structure, creates huge surface-area advantages over conventional lead acid grid structures. Active material utilization levels go from the historical 20-50 percent up into the range of 70-90 percent as well as enhanced fast-recharge capability and greater high-rate / low-temperature discharge times, according to Firefly. Costs to produce energy will be higher than conventional lead acid batteries, but below other new technologies, such as lithium batteries. Firefly hopes the approach will be competitive for electric vehicles under development. North Star Battery will produce prototypes for possible use by the US Army.
HP revealed more of its 3D printing plans in a recent webinar. Senior vice president of inkjet and graphics solution business Stephen Nigro spoke about how the technology works and expanded on HP's vision of open collaboration to commercialize its Multi Jet Fusion 3D printing technology for end-production, and open collaboration on new materials. He also said HP will create software to help users decide when to use Multi Jet Fusion versus conventional subtractive manufacturing.
A lightweight electric urban concept car designed by several European companies weighs only 992 lb without its battery. It would have weighed 26.7 lb more if its windows were made of glass instead of the specially coated LEXAN polycarbonate resin from SABIC Innovative Plastics.
Skylar Tibbits' team in MIT's Self-Assembly Lab is now 4D printing self-assembling shapes made of programmable carbon composites and custom wood grain. The composites are being used in a sport car airfoil, and the wood grain is beautiful.
The NanoSteel Company has produced high-hardness ferrous metal matrix composite (MMC) parts using a new nanosteel powder in a one-step 3D-printing process. Parts are 99.9% dense, crack-free, and with wear resistance comparable to M2 tool steels.
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