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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.

Mazda de Mexico celebrates 100,000th car built

Automakers and their factories celebrate production milestones all the time. Some are interesting enough to report on and some aren't, but what makes this one stand out is that the plant opened less than a year ago. Just 11 months since production began, Mazda de Mexico Vehicle Operation has put together its 100,000th vehicle – in this case a Mazda2 hatchback headed for Europe. MMVO is one of three plants assembling the company's smallest model, also known as the Demio in Japan, where it is also produced, with additional assembly taking place in Thailand under a joint venture with Ford. The Mexican location also handles assembly of the Mazda3 for the Americas and for Europe. Mazda has announced that it is expanding production at MMVO by 150 percent of this year's capacity to 250,000 units per year by March 2016 as it takes on contract manufacturing for Toyota as well.

Mazda goes on engineer hiring binge as recovery picks up speed

Japan's larger automakers - companies like Toyota, Honda and Nissan - have tremendous engineering talent at their disposal. That's largely because, selling as many cars as they do, they've got more revenues to tap into. Logic might dictate, then, that smaller automakers like Mazda, which no longer has the deep pockets afforded to it by its former partnership with Ford, might have less of a budget and workforce for engineering. But Mazda has been raking in record profits, and it plans on cashing those revenues in by hiring a substantial new pool of engineers.
According to Automotive News, Mazda is preparing to hire as many as 185 new engineers over the next two years - almost four times as many as the 50 engineers it previously targeted. Many of those engineers will be put to work developing the second-generation, Skyactiv 2 technologies that are on the drawing board while the first round of Skyactiv features are still being rolled out.
The boost in recruitment is enabled by a positive fiscal year that ended last March, marking the first profits Mazda had logged in four years. Sources anticipate that the fiscal year culminating at the end of this month will mark the company's most profitable yet, netting over a billion dollars to eclipse the fiscal year that ended in 2008 when it recorded $872.5 million in profits.