Manufacturing

Calculating the cost of 'going green' What are the costs of competing powertrain technologies, and how should engineers manage them to satisfy market and regulatory expectations—and make a profit? A value-engineering expert from FEV explains. Read full story

Hyundai adds turbo to Veloster lineup for 2013 The more powerful engine is the answer to reviewers’ calls for additional performance, with technology similar to the 2.0-L turbo in the Sonata, but developed for the Veloster's 1.6-L engine. An optional matte paint job is unique in its class. Read full story

Cleanliness is critical in fluid circuit components The evolving nature of the industry has resulted in strict standards concerning cleanliness in the fluid circuit and most other components of road vehicles such as brake systems, fuel injector nozzles, power steering pumps, and fluid hoses. Read full story

Controls system security an emerging trend on plant floors Preventing virus-compromised codes from causing disarray in the automated machines that handle crucial welding, assembly, and other tasks on the factory floor is gaining traction as an industry priority. Read full story

Developing steel cord reinforcement for injection molded parts BASF, Voestalpine, and Bekaert are working together to develop steel-cord-reinforced injection molded parts that the companies believe will make a significant contribution to vehicle safety. Read full story

Marsilli advances ‘open poles’ motor winding for hybrids According to Marsilli, a winding systems manufacturer based in Italy and an exhibitor at this year’s SAE World Congress, brushless motor design is facing a “revolution phase” as traditional needle-wound or field-coil motors have reached their maximum efficiency, being limited by the fill factor. Marsilli is advancing the open-poles motor winding concept to assist motor manufacturers in increasing motor performances and reducing material costs. Read full story

2013 Avalon styling surprises in New York It's the first Toyota car that not only was completely designed in North America at Calty, but also is being carried all the way through to production by the engineering team in Ann Arbor, MI. The new car takes a new direction in styling, is lighter, and puts more emphasis on handling. Read full story

Brembo sees high-performance brakes moving into more medium-price cars The Hyundai Genesis Coupe is one example, using a cast-iron rotor. An improved carbon-ceramic manufacturing process is sought to increase production and reduce cost. Fixed caliper design provides more uniform lining wear, reduced hysteresis, and better ABS response. Read full story

Laser R&D at German university helps carbon fiber make the cut University of Stuttgart Institute researches new processes for laser cutting of carbon-fiber-reinforced plastics (CFRPs). Read full story