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Tougher than steel: Wood pulp could make lighter auto parts

KYOTO, Japan — The global push among carmakers to make ever lighter vehicles is leading some auto suppliers in Japan to turn to what seems like an unlikely steel substitute — wood pulp. Japanese researchers and auto component makers say a material made from wood pulp weighs just one-fifth of steel and can be five times stronger. The material - cellulose nanofibers — could become a viable alternative to steel in the decades ahead, they say, although it faces competition from carbon-based materials, and remains a long way from being commercially viable.> Related: Jay Leno drives the Renew cannabis car — hemp you can't dent Reducing the weight of a vehicle will be critical as manufacturers move to bring electric cars into the mainstream. Batteries are an expensive but vital component, so a reduction in car weight will mean fewer batteries will be needed to power the vehicle, saving on costs. "Lightweighting is a constant issue for us," said Masanori Matsushiro, a project manager overseeing body design at Toyota. "But we also have to resolve the issue of high manufacturing costs before we see an increased use of new, lighter-weight materials in mass-volume cars."A NEW PROCESS Researchers at Kyoto University and major parts suppliers such as Denso Corp, Toyota's biggest supplier, and DaikyoNishikawa Corp, are working with plastics incorporated with cellulose nanofibers — made by breaking down wood pulp fibers into several hundredths of a micron (one thousandth of a millimeter). Cellulose nanofibers have been used in a variety of products ranging from ink to transparent displays, but their potential use in cars has been enabled by the "Kyoto Process," under which chemically treated wood fibers are kneaded into plastics while simultaneously being broken down into nanofibers, slashing the cost of production to roughly one-fifth that of other processes. "This is the lowest-cost, highest-performance application for cellulose nanofibers, and that's why we're focusing on its use in auto and aircraft parts," Kyoto University Professor Hiroaki Yano, who is leading the research, told Reuters in an interview. The university, along with auto parts suppliers, are currently developing a prototype car using cellulose nanofiber-based parts to be completed in 2020.

Mazda3 five-door vs. Mazda CX-3

As a talking point, it won't rival North Korea, world hunger or Mideast peace, but the ongoing tug between car and crossover continues to resonate in the hallways of Autoblog HQ. And it might also generate some discussion on Mazda showrooms, where the Mazda3 five-door and Mazda's CX-3 crossover are parked within a few feet of each other. Not only do they enjoy proximity on the showroom, but they enjoy/suffer (your choice, depending on POV) pricing proximity on the window sticker. The Mazda3 five-door is the more mature model of the two, having been introduced to a world market in fall 2003. With a commonsense footprint enclosed by almost-organic, upscale sheetmetal, the Mazda3 – especially in 5-door form – punches well above its weight in the still-nascent hatchback category. With a redesign (third-generation) introduced in 2014, along with a more recent refresh, the newest sedan and hatchback merge Mazda's KODO design philosophy with a responsive platform, available 2.5-liter drivetrain and a comfortable – if not expansive – interior. What the Mazda3 5-door (photo at left) does not give you is the crossover's high hip point, despite having ground clearance almost identical to the CX-3 subcompact crossover. And while the stated passenger volume of the Mazda3 and CX-3 is almost identical, those cubes are arranged differently; the Mazda3 offers an interior package more linear, while the CX-3 is more upright. Mazda's subcompact CX-3 (photo at top) is a more recent entry, having been developed from the Mazda2 architecture and hitting the street two years ago. It sits below Mazda's CX-9 and CX-5 in the Mazda pecking order. And it is tiny, on a wheelbase of just 101 inches and offering an overall length of just 168 inches. It is seven inches shorter than the Mazda3, with a wheelbase five inches shorter. The net effect is a more compressed environment for passengers, along with the very real challenge of fitting something inside – such as a bicycle – even when that something has its front wheel removed. In the city, I like the CX-3's compactness, and relatively unrestricted visibility when compared to the Mazda3's overall length and lower seating. But when both are equipped with their six-speed automatics, and the Mazda3 is spec'd with its available 2.5 liter DOHC four, there's almost no comparison in their performance. With that spec the hatchback has Mazda's well-hyped zoom, while the CX-3 makes do with nothing but a 4-cylinder boom.

2020 Mazda CX-30 small crossover lands an IIHS Top Safety Pick rating

The 2020 Mazda CX-30 has come out of the gate swinging on the safety front, earning the Insurance Institute for Highway Safety (IIHS) Top Safety Pick award in its first year on the market.  Mazda's new baby crossover earned a "Good" rating in all six of the Institute's crashworthiness categories (driver-side small overlap front, passenger-side small overlap front, moderate overlap front, side, roof strength and head restraint) and its accident avoidance system was rated "Superior." Sadly, only one set of available headlights was rated "Acceptable" or better, which kept the CX-30 out of the running for the coveted Top Safety Pick+ award. The best-rated lamps available on the CX-30 are actually those that come standard. The curve-adaptive units offered as an optional upgrade were rated "Poor" due to excessive glare. For 2020, IIHS made the guidelines for earning Top Safety Pick and Top Safety Pick+ awards even more stringent. Up until 2019, cars needed only to earn an "Acceptable" rating in the passenger-side small overlap test to qualify for a Top Safety Pick. For 2020, that has been raised to "Good."   The bigger challenge for many OEMs will be headlights. To earn Top Safety Pick+, a vehicle cannot be sold with any headlight configuration that does not earn at least an "Acceptable" rating.    So far, fewer than two dozen 2020-model-year vehicles for sale in the U.S. have met the criteria for Top Safety Pick+; roughly half again as many qualify for the lesser award. In coming years, the Institute is expected to add even more conditions, especially in the realms of accident avoidance and pedestrian safety.