The next generation of North American-built diesel engines, scheduled for introduction during the 2009 to 2011 timeframe, is a bright spot for an otherwise weak powder metal industry. New PM applications include cam gear drives, idler gears, timing system sprockets, and fuel injector gears. Powder-forged connecting rods and PM bearing caps are currently being tested and the outlook is good. General Motors put $69 million into its DMAX diesel engine plant in Moraine, OH to manufacture a new Duramax 6.6-liter V-8 turbo diesel engine that will meet 2010 emissions standards. DMAX Limited is a joint venture between GM and Isuzu Motors Limited and was established as a diesel engine company in 1998. About half of new cars in Europe feature diesel engines, which are more energy efficient than cars with spark ignition systems.
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.
Several new products in this group of new adhesives, coatings, and sealants are formulated to protect sensitive electronic components, or to seal components of commercial and military aircraft. Others are designed to operate in tough, messy, dirty oil & gas operations, or for rotary applications and motors.
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