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A 24-hour battle of speed and efficiency At Le Mans this month, amped-up hybrid prototype racecars from Audi and Toyota face a revamped Porsche 919 hybrid, while Ford hopes to recapture glory with its new GT-R. Pushing the ICE forward, gradually Emergent technologies from BorgWarner, Eaton and Mahle aim for greater efficiency in gasoline and diesel engines. Smile, you're on Magna camera! Magna Electronics is rapidly expanding production of its made-in-U.S.A. onboard cameras to keep pace with booming OEM demand for safety and vehicle-autonomy vision-systems technology. Multi-material body solutions: Possibilities and manufacturing challenges The body-in-white is a prime target for lightweighting and many automakers are pursuing unique and effective multi-material approaches, but improved design tools and processes might yield greater gains.

Defying the disruptors and driving innovation Four top engineering executives discuss how their "traditional" companies are finding new technology opportunities and business growth amid the start-ups-and are even doing some disrupting themselves. Preparing for a 48-volt revival The quest to improve fuel economy is not waning, nor is the desire to achieve higher mpg through the use of just the right lightweight material for the right vehicle application. Additive manufacturing enhances GTDI pistons Selective Laser Melting may help manufacture future gasoline-engine pistons with enhanced heat-transfer properties and reduced weight.

Clamoring for more entertainment Connected consumers drive demand for bandwidth, though seatback entertainment remains popular. Fighting for life in military markets Airbus Defense & Space is looking to revitalize and ramp up production rates of its military aircraft portfolio.

Uncertainty quantification The technique is a must for next-generation simulation tools. Oil-pump sizing Researchers from Hinduja Tech investigate options for low friction and power consumption. The future of Indian commercial aviation The growth in traffic that airport modernization has supported has also made a significant contribution to the local and national economies, while the improved infrastructure has been positive for the perception of India in the global market. Driving EVs toward lower cost The race ison to reduce battery and electric-drive systems cost while improving efficiency. Powering on Rolls-Royce's Chief Engineer discusses new technologies that inspire current R&D design and evaluation work as part of its strategic roadmap for future big commercial programs. HMIs extend beyond the cab Telematic functions are being integrated into multi-function user interfaces.

GM's CTO driving new paths to technology leadership 'We're making actual production commitments regarding our advanced-technology strategy, rather than just talking about it,' says GM's CTO Jon Lauckner. 'We're absolutely going to be among the leaders, if not the leader, in these areas.' Aluminum prepares for its next big leap Ford's F-Series blockbuster was just the beginning. New micromills now in pilot phase aim to bring vastly stronger and more formable light-alloy materials at higher capacity, says Alcoa's Mike Murphy. Slick solutions for friction reduction From new lubricants to 'smart' oil pumps and clever bearing technologies, engine designers are attacking every potential source of spin losses and internal friction in the quest for more mechanical work out of less fuel. Next-gen NSX: a twin-turbo, multi-material Ferrari-fighter The production NSX made its much-awaited global debut at NAIAS in January.

Calibration and complexity Off-highway engine applications continue to increase in complexity to meet emissions regulations and fuel economy targets as well as to take advantage of advances in electrification and mechatronics. The model-based calibration process has become the industry standard. ECU advances take many paths Controllers are evolving rapidly, with a range of microcontrollers distributed throughout the vehicle Working remotely A new electrohydraulic steering technology that offers energy efficiency improvement, increased productivity, enhanced safety, and adaptability to operating conditions also has the capacity to support remote operation of a compact wheel loader.

Women in Vehicle Engineering Across the industry, talented women are ascending the engineering-career ladder at higher rates than ever before, but they continue to face challenges in a male-dominated industry. In this Special Report, AE speaks with current and future industry leaders from U.S., European, and Asian OEMs, academia, and other experts, and analyzes data, to assess progress to date and plot the future of this critical and dynamic professional trend. Fuel cells As higher-volume mass production gets underway, OEMs and suppliers are finetuning their capabilities.

A new Formula for racing The new Formula E series' electric racecars are intended to pioneer new technology for broader use in production, encouraging fans to think differently about the technologies they use. Production of satellite with first all-electric propulsion system advances Electric propulsion has been limited so far to small movements of the satellites once it is in its geostationary orbit. The Boeing 702SP innovation is its use of electric propulsion to raise the satellite from its launch-vehicle drop-off point to geostationary orbit. Using CAE to assess whining noise of electric powertrains To develop an electric powertrain with a minimum noise level and minimized whining it is necessary to have accurate CAE simulation and precise criteria to assess whining noise.

3-D manufacturing of titanium components takes off MRO providers are discovering ways to innovate their procedures while remaining viable and profitable through the current downturn in government spending. Commercial programs are flying high With economic regeneration underway this year, the rate of ordering new aircraft has been at an all-time high, with the result that backlogs for undelivered new production stretch well into the next decade for some popular models.

Systems-engineering a new 4x4 benchmark Chrysler Powertrain teamed with AAM to create the industry's most capable, sophisticated-and arguably most fuel-efficient-AWD/4WD driveline. Top engineers talk about their collaboration. Achates aims at 2025 light-truck power After more than a decade of steady development, Achates Power's opposed-piston two-stroke diesel is impressing powertrain experts with its test results and pace of technical progress. Lighter, stronger chassis Development of a new high-strength aluminum casting alloy for the production of suspension components.

Making sense of hybrids Developers focus on applications that boost productivity while they strive to improve the efficiency of alternative power sources.

'Brands are king' is the credo for Chrysler engineering Senior VP of Engineering Mark Chernoby reveals what makes his revitalized team so effective, why it's unique-and what's missing in its connection with Fiat. Directing Tesla's unique trajectory JB Straubel wears far more hats than most automotive CTOs. He talks about vehicle development, his engineering team, and what they've got in the works. Engineering Ford's global product assault Hau Thai-Tang details how his global product development teams are changing to keep pace with faster product cycles, greater product diversity, and an avalanche of new technologies. (Hint: They're benchmarking the CIA.) Closing the hybrid control gap Virtual sensing, architectural tweaks, and faster processors help engineers narrow the cost gap between hybrid and conventional powertrains. Radar love An emerging crop of autonomous vehicles uses ever-vigilant sensors to find their way and avoid collisions.

Next-BIG-Thing Clemson students, with the help Mazda and others, show their concept for practical Gen Y targeted car that could be marketed at a price of about $28,000. Collision welding An academic group at The Ohio State University is developing breakthrough new high energy density methods for enabling dissimilar metal joints. Carbon fiber, new aluminum structure lighten 2014 Corvette Stingray The C7, which enters production in 3Q13, boasts an all-new aluminum chassis/passenger cell structure that is 57% stiffer in torsion and 99 lb (45 kg) lighter than the previous C6 steel-and-aluminum structure.

Shed a few joules with better aerodynamics A team of engineering students from Laval University has managed to reduce the energy demand due to wind resistance of its Supermileage vehicle by 10% after carefully designing a new vehicle body with a 25% larger frontal area. Telemetry helps Formula SAE team close the loop on design Once a year, a team of students at Virginia Tech get to do something that ought to put a grin on any aspiring engineer's face: build a racecar. Unconventional steel wheel designs The drawings done by collegiate students for a steel wheel design competition had industry professionals thinking about future production possibilities.

The big engine that could With the stringent EPA 2015 regulations on large diesel engines for locomotive, marine, and stationary generator applications, the need for NOx reduction via urea SCR catalyst arises given the proven performance of urea SCR. Monitoring hydraulics Component producers and vehicle service providers offer their views of hydraulic diagnostics as the industry moves toward real-time, intelligent health monitoring, predictive failure software algorithms, and wireless notification. Engine management expands from minute movements to full vehicle Electronic controls grow in complexity as engine designers extend their scope to include hydraulics.

Putting electrification to work For fleets, going green is a high priority-but making green is an even higher one. A move to 'more electric' engines Researchers detail a motor control design for the fuel system of a more electric aero engine, focusing on the necessary safety and reliability aspects. 2012-13 Hybrid Vehicles Guide A quick reference to the latest production HEVs and their key specifications.

Driving the pace of change Engineers speak out on software's impact on the automotive industry in online survey. Inside ZF's nine-speed transaxle for 2012 AEI travels to Friedrichshafen for an exclusive look at the development and technology behind the 9HP--the industry's first nine-speed transaxle slated for MY2013 production. Technology crosses industry borders Between the commercial- and military vehicle markets, knowledge sharing and tech transfer benefits both in areas such as vehicle electrification and altenative fuels. Cutting the cost of carbon Automakers streamline production to reduce the price premium for lightweight carbon fiber.

Small car, big project Vehicle Line Executive for the Fiat 500, Joe Grace, talks about bringing the iconic car to North America and the collaboration between engineers in Turin and Detroit that helped make it happen. Girding the grid for EVs Public electric utilities such as Detroit Edison have a virtual role to play in cultivating the electric vehicle market. Progress, new innovations spur GM;s fuel-cell development Fuel-cell program Executive Director Charlie Freese reveals the ongoing technical progress aimed at making FCVs part of GM's production vehicle portfolio later this decade. Planning the future of PLM and 3-D virtual tools The product-development revolution that began with CATIA is only beginning, says Dassault Systemes' CEO Bernard Charles.

Future testing of active safety systems To speed up the introduction of active safety systems, efficient standardized test programs are needed, including alternatives to test-track testing. Engine management on a budget Tata Technologies engineers at the recent SAE Convergence event provided an inside look at how they developed the Nano's low-cost EMS and reduced development time and cost with extensive use of modern tools. Racing for the green Changes are coming to Indy Car and Formula One to focus on green technology that applies to production vehicles. Taking strides together SAE 2011 World Congress host company General Motors touts teamwork as a way to expand industry knowledge and encourage energy efficiency.

Why Volt? After 48 months' development, the 2011 Chevrolet Volt has enetered series production. The pioneering "E-REV" is as important to the mobility industry as it is to GM. Creating the heart of Volt GM's battery requirements meant creating new state-of-the-art in-vehicle engery storage - and doing it in less than four years. Top GM and supplier engineers reveal how they did it. Engineering with maniacal focus A dedicated, cohesive team and a conservative engineering approach put this innovative vehicle into production at moon-shot speed. A unique electrified transaxle Hybrid or not? Definitions aside, what really matters is GM wisely leveraged its next-generation Two Mode propulsion technology to give Volt greater overall efficiency. Sweating the body details Extensive wind-tunnel work gave Volt a shape that's slicker than it looks. But engineers aren't happy with the curb weight.