The production version of the Chevy Volt introduced in Detroit Tuesday by GM CEO Rick Wagoner revealed a car with a less striking design than the concept car shown in January 2007. Well, the materials used in the car are also taking a more conventional path. The body of the concept Volt used new high-performance composite technology (HPPC) developed by GE Plastics (now Sabic) that featured a sandwich of glass mat and thermoplastics made with regenerated plastic scrap. Bob Nelson, Automotive Executive Marketing Director for Sabic Innovative Plastics, says: “The new commercial Volt that was launched/announced earlier this week does not have any of our composites that we demonstrated on the concept vehicle with GM. We have several successful development programs going on with IXIS but the timing was such that the technology was not going to be ready to put on the Volt. The advantages of IXIS in cycle time and weight reduction and the new product launch of IXIS 157 are being well received by our customers. We will have more to discuss in the future about which vehicle platforms this technology will be on in the future.” There’s no word from GM on the materials used in the production Volt. Undoubtedly, though, the new, lighter advanced steels will play a big role. GM has a few issues to settle with the battery technology before it makes decisions on body tooling.
GM was surprised by the wave of excitement surrounding the Volt concept car last year. Concept cars are just a beauty pageant side show at the Detroit auto extravaganza. Often suppliers, such as GE, would provide much of the money and muscle to demonstrate ideas. Designers are told to use a blank sheet of paper without great concern for production issues. The Volt suddenly became the centerpiece of the future of General Motors, primarily because of its power train. That’s why the production Volt now looks more like a real car.
Producing high-quality end-production metal parts with additive manufacturing for applications like aerospace and medical requires very tightly controlled processes and materials. New standards and guidelines for machines and processes, materials, and printed parts are underway from bodies such as ASTM International.
Although plastics make up only about 11% of all US municipal solid waste, many are actually more energy-dense than coal. Converting these non-recycled plastics into energy with existing technologies could reduce US coal consumption, as well as boost domestic energy reserves, says a new study.
This year's Dupont-sponsored WardsAuto survey of automotive designers and other engineers shows lightweighting dominates the discussion. But which materials will help them meet the 2025 CAFE standards are not entirely clear.
Artificially created metamaterials are already appearing in niche applications like electronics, communications, and defense, says a new report from Lux Research. How quickly they become mainstream depends on cost-effective manufacturing methods, which will include additive manufacturing.
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