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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.

Recharge Wrap-up: Toyota FCV wears silver, Foxconn's $15K EV, solar power at GM

The Toyota FCV made its North American debut at the 2014 Aspen Ideas Festival, and this time it's not sporting its usual blue sheet metal. This silver paint job shows a bit more contrast. Certain features stand out a bit more, especially the black strip that wraps around the grille and down the sides of the hood to the mirrors. This is the production version of the car's exterior, which will go on sale in California next summer. Toyota also had its Driver Awareness Research Vehicle, DARV 1.5, on display in Aspen. DARV 1.5 uses technology to decrease driver distraction and measure driver behavior to provide a safe driving score. See more of both cars in our image gallery. Taiwan's Hon Hai Precision Industry (also know as FoxConn Technology Group) says it is planning to build electric cars that will cost just $15,000, according to The China Post. The world's largest electronics maker, which assembles mobile devices for Apple, promises that the cars will be highly connected. "When integrated with cloud computing, the Internet, smart traffic and smart cities in the future, people will be able to drive more easily and reduce car accidents more efficiently," says Hon Hai chairman Terry Gou. At a shareholder's meeting, Gou didn't comment on production timing or other details about the cars, nor would he answer questions about possible cooperation with Tesla Motors. Hon Hai made headlines in recent years after a series of employee suicides, which led the company to raise worker wages and install anti-suicide netting on its buildings. EV advocates in Illinois took a 500-mile road trip to help temper range anxiety in potential buyers, says the Chicago Tribune. The demonstration, organized by the Illinois Green Economy Network, meant to show people that they can use electric vehicles to drive long distances without getting stranded with a dead battery. The drive began near Carbondale and traveled to 11 different community colleges with charging stations before terminating in Grayslake. Illinois has about 5,000 registered electric vehicles, and 450 public and private charging stations. General Motors is building three acres of new solar arrays to produce an expected 400,000 kilowatt-hours of renewable energy per year. The new arrays at GM's Swartz Creek processing center and Flint engine plant will be completed this fall, contributing to the company's 38 megawatts of solar power from facilities around the world.

TMG's super Lexus LS Sports 650 gets track tested

The people at Toyota Motorsport GmbH have been responsible for the Japanese automaker's motorsports efforts since the 1970s, but since Toyota pulled out of Formula One after the 2009 season, the tuning shop has been developing a super sedan based on the Lexus LS called the Sports 650. Details on TMG's first road car have been scarce, but XCAR was recently invited to drive the 641-horsepower Lexus on track.
Here's what we know: the Sports 650 has enough power to sprint to 60 miles per hour in under four seconds, tops out at 199 mph, weighs over two tons and utilizes LFA brakes. Oh, and its twin-turbo V8 bellows like an AMG V8. That last part isn't surprising when considering TMG could become Toyota's in-house tuning arm - like AMG is to Mercedes-Benz. As for the bespoke body kit, fender flares and stacked exhaust pipes? They fit the car well and even remind us a bit of Lexus' other high-performance sedan, the IS F. Currently there are no plans for the Sports 650 to be made into a production car, but we doubt TMG is devoting this much effort developing the LS into a road-rocket for nothing.
Check out XCAR's video below to see the AMG-fighter wrung out on track, and then ponder what could be if TMG were let loose to fiddle with other cars in Lexus' lineup. Now that's something we could get used to!