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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.

Lexus gets new boss, and he's a designer

A reshuffle in the uppermost ranks of Lexus could see the Japanese luxury brand further energize its recent focus on design. Tokuo Fukuichi, Toyota's global design boss, is the new head of Lexus International.
Fukuichi will retain his role as the overall head of design for Toyota, Lexus and Scion, and will assume his new position at the head of Lexus and on its board on April 1 (no fooling). This is going to be an interesting move for fans of design to watch, as Fukuichi has repeatedly been mentioned as a designer that enjoys pushing the edge of the envelope and experimenting. He is, after all, the man responsible for designing the most awesomely odd minivan of the 1990s, the mid-engined, rear-drive Toyota Previa, and more recently, he signed off on the controversial Lexus LF-NX concept, which is said to presage a new production small crossover.
"Regarding changes in design, no one has 100 percent confidence," Fukuichi told Forbes back in January 2013. "No one can really say with pure certainty that, 'In two years, this will sell well.'" As Akio Toyoda continues to demand more assertive, edgier designs, it's that point of view that should make Fukuichi a valuable addition to Lexus, as it continues to challenge the competition from Germany.

Two new RWD Toyota sports cars to join FR-S?

Toyota as we know it could become a thing of the past. According to Australian site Car Advice, the Japanese brand known for bland cruisers like the Camry and Corolla is preparing to bring two new rear-drive cars to market that would slot above and below the Scion-badged FR-S. This is very, very good news.
Car Advice spoke to the GT86/FR-S' chief engineer, Tatsuya Tada, who claimed, "Akio Toyoda always says to me, Toyota sports car [family] should be three sports car brothers. 86 is in the middle." The oldest "brother" would be the spiritual successor to the Supra, even if it doesn't wear that name. Tada is in charge of that project, while a sub-GT86 project is being headed-up elsewhere.
Tada refused to comment on names (CA specifically mentions MR2 and Celica) for the new small car, but did say that, "Yes it is rear-wheel drive and that's Toyota's strong position - Toyota sports car must be rear-wheel drive." Perhaps the juiciest bit of information obtained from Tada's interview with Car Advice was his hinting that both new sports cars would be joint ventures, like the GT86/FR-S/Subaru BRZ triplets. Tada wouldn't say who Toyota was in bed with on the smaller model, but did mention that the Supra would be a product of the world's largest automaker's partnership with BMW.