An injection-molded oil pan design for Mercedes-Benz large, heavy-duty truck engines is made of polyamide resin. It weighs half as much as the aluminum version, reduces sound, resists damage, and integrates more components. (Source: DuPont)
I agree with the concept of using polymers will decrease emissions and will certainly help with fuel efficiency but what happens to safety standards when more and more parts are being manufactured using these types of plastic?
I think until 2009, the auto industry could sell tons of cars without much innovation. That changed with the near-death expierence the auto industry experinced in 2009. Add to that the impending CAFE standards and you get forced innovation.
As I understand it, these engineering materials had often been developed for other applications but could be adapted without much hassle to the needs of cars, starting with the interiors and non-structural apps. I think it was, and is like we discuss in this article, more a matter of marrying the material with the app. Some of these materials have already been used in other vehicle apps like heavy trucks or airplanes.
It's also true that materials suppliers, especially plastics companies, have had products that were at least potentially applicable to automobiles for several years before car companies began even considering the possibility of implementing them. But that's at least partly because trying to insert any new material or process into the incredibly complex, high-speed auto manufacturing line requires a lot of time and effort. It can't be done quickly.
One thing I'm seeing in the auto industry is the role of the suppliers in technology development. Lear, for one, is developing entire drive chains for the hybrids and EVs of their customers. I asked a Lear engineer who owns the IP on this and he said it was Lear. That means a good percentage of the IP on some vehicles is not even owned by the carmaker.
Jmiller, I agree that car companies are stepping out with innovation now. But I don't think they were being particularly innovative 10 or 15 years ago. Also, let's give a great deal of credit to the suppliers. In many cases, the car companies asked suppliers to come up with innovative solutions.
A make-your-own Star Wars Sith Lightsaber hilt is heftier and better-looking than most others out there, according to its maker, Sean Charlesworth. You can 3D print it from free source files, and there's even a hardware kit available -- not free -- so you can build one just in time for Halloween.
Some next-generation bio-based materials are superior in performance to their petro-based counterparts, but also face some commercial challenges. This is especially true of certain biopolymers, adhesives, coatings, and advanced materials.
Cars and other vehicles, as well as electronics and medical devices, continue to lead the use cases for the new plastics products we've been seeing, as engineers design products for tougher environments.
LeMond Composites, founded by three-time Tour de France cycling champion Greg LeMond, is the first to license a new carbon fiber production method invented by Oak Ridge National Laboratory (ORNL) that's faster, cheaper, and greener.
This month will mark the launch of the SpeedFoiler, a super-fast, ultra-lightweight foiling catamaran that can fly short distances over water faster than other foiling designs, in part because of its carbon composite materials.
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