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Manufacturing Process

Automotive Design's feature library provides editorial features classified into key automotive design industry sector topics such as this Manufacturing Process section.

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Cutting costs of carbon composites	27/02/2013
Automotive lightweighting needs drive progress toward cheaper fiber and high-throughput processing.

Composites simulation can accelerate acceptance	21/02/2013
David Mason, Vice President of Global Automotive for Altair Engineering, discusses how modeling and FE analysis tools can help engineers optimize their structural composite designs—and ultimately "catalyze composites growth" in the automotive sector.

Mazda's new system machines blocks with different bore centers	04/02/2013
Just four four-axis CNC machines handle four-cylinder engines from 1.3 to 2.5 L, plus a 3.7-L V6 and reduce block machining time from 6 to 1.3 h.

Johnson Controls concept interior is well-tailored	15/01/2013
Coining a British term that describes well-tailored attire, the Bespoke interior concept represents Johnson Controls' design pitch for a premium vehicle.

SAE Online Poll: Cost still No. 1 hurdle to high-volume composites use	04/01/2013
Cost remains the most significant challenge to overcome for composites to be more widely deployed in high-volume vehicles, according to a recent poll posted on AEI Online. Repairability was second, manufacturing/assembly third.

Mass production of composites solved	27/11/2012
Rani Richardson, product specialist at Dassault Systèmes, reports on a potential key to unlocking carbon fibre's assembly potential

GM tools up for high-volume aluminum structures with new welding technology	24/09/2012
The process centers on a new electrode-tip design. It will enable GM’s global body shops to spot-weld virtually any combination of aluminum sheet, extrusions, and castings at higher production rates than are currently used in automotive aluminum-structures manufacturing.

Oak Ridge collaborates for cheaper carbon fiber	27/08/2012
Lightweight vehicles of the future will require strong carbon-fiber composite structures, but low-cost fibers are needed for market viability. Overcoming the challenges to cheaper carbon fiber is exactly what a research team at Oak Ridge National Laboratory is aiming to do at its new Carbon Fiber ... Read more

Kuka robots get faster, stronger	23/08/2012
Agile robots. Stronger robots. And robots that can be programmed using computer numerical control (CNC) language took the spotlight during Kuka Robotics' first-ever technology event showcase.

Precision shaft metrology with no strings attached	09/01/2012
Bruker has a new tool, the NPFLEX-LA optical microscope, for measuring shaft smoothness.

Building the V8 power behind McLaren’s MP4-12C supercar	30/12/2011
Bespoke manufacturing techniques help Ricardo build the engine of McLaren's ultrahigh-performance sports car.

GM aims to double brake rotor service life with new FNC treatment	08/12/2011
General Motors patented the ferritic-nitro carburizing (FNC) process and will apply it to 80% of its U.S. production brake rotors by 2016. Shiny, hard-wearing rotors are the result.

Kemet goes big on capacitors for EV inverters	08/12/2011
The average car finds use for about 5000 capacitors, according to Kemet, one of the world’s largest suppliers of the types used in automobiles.

New cathode materials, manufacturing gains will cut Li-ion costs	15/11/2011
The cathode is the "energy-carrying heart" of the lithium-ion battery, according to Umicore's Tom Van Billinghen, and rethinking its materials and design is key to helping to reduce Li-ion battery costs.

Towards a lightweight future	01/11/2011
Aluminium is stepping out of the shadows of steel to become the material of choice for vehicle makers as they strive to make their products lighter, more efficient and more environmentally friendly. By Daniel Jubera, Novelis director sales and marketing automotive Europe

Overcoming overspray	01/09/2011
VW's new US plant employs a highly innovative paint system, as Paul Weissler discovers

The weighting game	01/09/2011
Paul Meeson, Stadco's advanced engineering director, talks with Ian Adcock about the revolution in body assembly that will drive down vehicle weight and manufacturing costs

‘Buy to drive’ Manufacturing	01/08/2011
This nylon plenum chamber was made using selective laser sintering by 3T RPD Ltd for the University of Hertfordshire

Bridging the gap	01/08/2011
The trend in green manufacturing is rapidly spreading across the motor industry. Ian Adcock visits Bridge of Weir leather to witness at first hand its green revolution

Two-metal cradle from Cosma is production-ready	14/03/2011
Cosma International engineers have produced a bimetallic engine cradle that meets General Motors' design and performance requirements.

The new black	01/03/2011
The best way to cut your carbon footprint could be to use carbon fibre. Ian Adcock, Paul Horrell and Lou Reade investigate.

Frimo flaunts new production facility	01/01/2011
Automakers and the supply chain are checking out the latest machinery for assembling instrument panels, door trim, headliners and other interior plastics at a new technical centre in Michigan, USA. Kami Buchholz reports

2011 Pentastar is Chrysler's new do-it-all V6	15/12/2010
Designed to support turbocharging, direct injection, MDS, and even Multi-Air, Chrysler's new V6 launches a new era of powertrain simplicity for the re-emergent automaker.

Johnson Controls simplifies process for distinct seats	06/12/2010
The supplier has introduced a high-frequency (HF) welding system, enabling designs and 3-D imprints to be applied to trim covers of different quality via a simplified process.

How Jaguar lightens up the XJ	30/11/2010
Fitting sunroofs to cars may be a long-established area of manufacturing capability, but for the Jaguar XJ sedan’s Webasto opening panoramic roof it is almost a balletic performance.

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