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.
New versions of BASF's Ecovio line are both compostable and designed for either injection molding or thermoforming. These combinations are becoming more common for the single-use bioplastics used in food service and food packaging applications, but are still not widely available.
The 100-percent solar-powered Solar Impulse plane flies on a piloted, cross-country flight this summer over the US as a prelude to the longer, round-the-world flight by its successor aircraft planned for 2015.
GE Aviation expects to chop off about 25 percent of the total 3D printing time of metallic production components for its LEAP Turbofan engine, using in-process inspection. That's pretty amazing, considering how slow additive manufacturing (AM) build times usually are.
For industrial control applications, or even a simple assembly line, that machine can go almost 24/7 without a break. But what happens when the task is a little more complex? That’s where the “smart” machine would come in. The smart machine is one that has some simple (or complex in some cases) processing capability to be able to adapt to changing conditions. Such machines are suited for a host of applications, including automotive, aerospace, defense, medical, computers and electronics, telecommunications, consumer goods, and so on. This radio show will show what’s possible with smart machines, and what tradeoffs need to be made to implement such a solution.