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Tesla casts a new strategy for lightweight structures The EV maker boldly invests in the world's largest aluminum die-casting machine to manufacture entire rear underbody structures. Steel the Real Deal Steel's infinite recyclability will help it remain the auto industry's material of choice, insists Tata Steel Europe's CCO. Tesla's Cybertruck is audaciously austenitic A proprietary 301-series stainless steel gives Tesla's first pickup truck unique sales attributes while saving tooling cost. Lightweight design beyond CAD New computational tools enable an integrated data-fusion approach to complex, mixed-materials engineering. An expert from nTopology explains. Editorial Impressions of a rocket launch SAE Standards News New Cooperative Driving Automation standard provides clarity to support advancement of full automation Supplier Eye Now comes product-cadence chaos What We're Driving Can CHAdeMO 3.0 standardize global EV quick-charging?

Hot-stamping process Hot-stamping process from Schuler employs flexible 'pressure controlled hardening' Fuel cell futures no longer a dream Fuel cell technology is catching up with the hype as fuel cell vehicles become reality. Hot Technologies 2016 Our annual review of significant, innovative, and just plain cool technology applications for the new model year.

Virtual casting improves powertrain design As designers continue to look for ways to cut weight and increase performance, casting simulations are helping optimize designs through faster, more accurate predictions of the casting process used to create key components. Horse racing America's pony cars are a favorite of racers and fans alike, so racing them against each other is natural. SAE 2015 World Congress Preview Tech trends and exhibitor products are highlighted. Tech trends and exhibitor products are highlighted in this special section, which features an exclusive interview with Honda R&D America's Jim Keller. Replicating the racing experience Professional driving simulators can be successfully exploited to shorten the traditional design-prototype testing-production process relative to a new racecar.

What's New at ConExpo/IFPE A preview of some of the new products and technologies that companies plan to showcase at this year's ConExpo-Con/Agg, which is co-located with the IFPE fluid-power event in Las Vegas from March 4-8. Injection strategies for improving emissions characteristics Premixed charge compression ignition reduces NOx and soot emissions, but requires the optimization of the injection timing and pressure, fuel mass in pilot injection, and EG R rate. Systems that talk together, are efficient together Design teams take a holistic view, linking engines, transmissions, hydraulics, and aftertreatment systems to boost efficiency and performance. Managing the deluge of data The model-based development (MBD) process has been a key enabler of technical advancement in the transportation industry; however, the MBD process leads to the generation of large volumes of data artifacts and work products.

Global Viewpoints - Europe: Smartening up R&D As every aspect of automotive technology makes rapid advances, R&D becomes ever more complex and faces additional pressures on cost and time. In our annual report from Europe, we spoke to very senior executives about their R&D methods and the demanding criteria they face. LEDs light the way for SuperTruck A research team developed a group of low-energy; high-output LED lamps for forward lighting that could be retrofitted into the truck's current incandescent headlamp housing and lens. Plastic proliferation under the hood Plastic components continue to displace metal engine parts because of cost and weight advantages.

Valve controls Imagine a valve control system that is infinitely variable irrespective of engine speed and load. Impossible? Not according to Camcon Automotive's technical director Roger Stone, as Ian Adcock discovers Mother Nature knows best What can the automotive industry learn from nature when it comes to weight saving? Ryan Borroff has been finding out Building up the pressure Tony Lewis reports on the growing trend towards even higher line pressures in injection systems.

Simulation helps manage change in aircraft manufacturing Commercial aircraft demand is up even while sequestration and other forces are forcing scale-backs in defense-related programs. From managing complex supply chains to improving scrap rates in casting, digital simulation is proving a valuable aid.

Bracing for success Cast reinforcements spectacularly boost torsional rigidity and improve steering precision.

BMW readies mainstream carbon-fiber vehicle structures for MY2014 The partnership with SGL Composites is already making parts for the 2014 BMW i3 and i8. AEI visited the pioneering U.S. carbon-fiber plant and witnessed a potential emerging challenger to aluminum for vehicle lightweighting. Driving a safety 'brake-through' As pressure grows for accident-free travel, EuroNCAP is pushing for widespread adoption of autonomous emergency braking (AEB) systems as a way to avoid accidents caused by late braking or braking with insufficient force. A history of leadership Ten years after completing his term on the SAE Board of Directors, Argonne National Laboratory's Donald G. Hillebrand takes on another role-2013 SAE President.

Advances in simulation deliver better engines Engine developers need to deliver cleaner engines that burn less fuel, are more durable, and quieter. If that was not enough, competitive pressures are forcing them into shorter time lines and reduced budgets. Engine developers may have no other opportunity to reduce cost and risk than use more CAE simulations.

CAE simulation and test advance together With increasing pressures on companies to develop products faster with less cost, CAE simulation and physical test forge stronger ties.

Up in arms over robots As one-armed robots improve in accuracy, gradually expect to see more of them as the pressure grows in aerospace to augment manual labor.

Tier 4 puts pressure on hydraulics Smaller pumps, smarter controllers help maintain power levels even as engine power declines.

Synchronized driving Tight linkage between engine and transmission increases efficiency. Sensing a change Hydraulic engineers are being pressured to design systems that perform more tasks while taking less space. Steel still king Advanced steels and processes offer better performance and lower cost, particularly in powertrain applications.

Shrinking hydraulics The push to conserve fuel and reduce emissions is prompting major changes in system design. Aftertreatment temperature control Regeneration of a DPF burns off soot, but also raises exhaust gas temperature. Speed thrills: doing more tests in less time Quicker data gathering, simulation keep quality high despite time crunch. Green engineering The quest to alleviate environmental and efficiency pressures turns up 'small' material solutions with big benefits. A global forum Cummins executives lay the groundwork for a lively and informative discussion at this year's Commercial Vehicle Engineering Congress & Exhibition.

Motors play an important EV roles Though lithium-ion batteries grab much of the spotlight, improved electric motor technology is crucial in advancing the operation of battery, hybrid, and plug-in electric vehicles. The quality race continues As end-user expectations continue to rise, and pressure on engineering and manufacturing processes spiral, AEI's European Editor interviewed a number of OEM executives for their thoughts on quality and strategies for better vehicles. The real world Convergence 2008 will place emphasis on the challenges of determining and meeting customer needs in creating better electronic systems. A new generation of engine efficiency New technologies help to maximize fuel efficiency, reduce emissions, and deliver market-pleasing performance.

In search of the perfect burn The simultaneous download pressures on NOx and PM continue to make research into higher injection pressures and alternative combustion solutions such as homogenous-charge compression ignition attractive. One way to stop a train A new self-energizing electrohydraulic brake offers the advantages of hydraulic brake actuation without the disadvantages of a centralized hydraulic power supply. A model combustion: from art to science Analysis tools, advanced hardware provide insight into combustion process, refining the cylinder's 'big bang.' The datalinked vehicle In the fields and on the job site with GPS.

Cadillac CTS GM's all-new global sports sedan makes no excuses in chassis dynamics, body integrity, powertrain performance, premium materials, and overall craftsmanship. Taking control of hybrids Software must monitor and manage many parameters while coordinating the complex operations of the engine, electric motors, and batteries. LIghter, faster, lower cost Ducati's top engineer brought a "maniacal" approach to developing the 1098 superbike. Diesels' brave new year Lean-NOx catalysts, closed-loop cylinder pressure sensing, and homogenous combustion are making "50-states" diesels a reailty. Behind the curtain AEI takes an in-depth look at how the designers and engineers at General Motors took the company's trio of new crossover SUVs from sketchbook to road. Engineering from everywhere With future growth in car and truck sales coming mainly from emerging markets, companies are realigning their engineering operations accordingly.

Where intelligence goes Changes in distributed or embedded control as well as processor power are altering automotive computing hierarchy. Making chassis magic Nothing beats veteran ride-and-handling engineers in creating a truly integrated chassis. But simulation is increasingly vital to their seat-of-the-pants development work. Mass reduction--the next frontier Automakers turn their attention to reducing vehicle weight in the quest for greater fuel efficiency. Electricity drives forward Continuous advances in component design and integration are helping to overcome cost and performance obstacles. At your service As cost and human-resource pressures mount, testing and engineering outsourcing heats up and alters roles within the industry. Finding the right Formula The University of Wisconsin-Madison won the annual Formula SAE student competition held in Michigan, beating more than 130 other teams aiming to conceive, design, and fabricate the best, small formula-style racing car.

Spec Formula One The series is moving forward with new rules to reduce cost and make racing more directly relevant to road-car development. Adding foresight Radar and cameras will work together to help drivers avoid accidents. Lexus LS 460:AEI's Best Engineered Vehicle for 2007 The fourth generation of Lexus' global flagship sets new standards in engineering, technical innovation, refinement, and workmanship. Hot off the grid New interest in plug-in hybrids has sparked intense R&D in battery chemistries and systems integration. Digital developments Ever-improving computer-based tools are helping engineers complete more complex designs in shorter time frames with downsized staffs. Illuminating technology Sensor-linked lighting systems, automatic high-beam control, LED headlights, and brand-identifying cabin lighting are enhancing safety, convenience, and the feel-good factor.