Don’t be surprised if Japanese OEMs lead the way on what my be the next big technology leap in mass-market auto design—bodies made with advanced plastic composites like those used in the Boeing Dreamliner still under development. Boeing’s sole supplier for the enormous amounts of composites required for the plane is Toray Industries, which co-located a production plant next to Boeing’s assembly factory near Seattle, WA. Toray is rapidly ramping up capacity to meet demand for the 787 and other projects, including future Airbus planes. Toray recently established a $24 million automotive center in Nagoya, Japan to develop advanced composites for cars. Its main mission will be to make the new lightweight systems more affordable. Use of carbon-fiber reinforced panels in the body of the new Tesla (all-electric) roadster adds $3,000 in cost per car—way more than cash-strapped American OEMs (and customers) can afford now. Regular fiberglass composites, such as those used on the Corvette, are less expensive, but much heavier.
Norway-based additive manufacturing company Norsk Titanium is building what it says is the first industrial-scale 3D printing plant in the world for making aerospace-grade metal components. The New York state plant will produce 400 metric tons each year of aerospace-grade, structural titanium parts.
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.
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