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2016 Chevy Malibu exhaustively tested with four decades of data

Chevy is preparing to unveil its new Malibu sedan at the upcoming New York Auto Show next month. But when it does, it's not like it will have appeared overnight. The development of any new vehicle – especially one as widely produced by a major automaker as the Malibu – involves rigorous and relentlessly punishing tests. In the Malibu's case, that meant 1.5 million miles of driving from the scorching heat of Arizona in July to the frigid cold of northern Canada in January and everything in between. The Bowtie brand also says it incorporated four decades' worth of data taken from vehicles driving in locations around the world since 1972 in order to make the Malibu the best it could be. We'll have to wait to find out the results of all that exhaustive testing, but you can catch a sneak peek at the new sedan in the video above. Four Decades of Data Used to Test 2016 Chevrolet Malibu Recorded customer use drives durability testing for next-generation midsize sedan 2015-03-11 DETROIT – Data collected over decades from across the globe is helping ensure the 2016 Chevrolet Malibu can handle the world's worst roads even if the all-new midsize sedan never drives on them. Data collection boxes are placed in cars in real-world driving conditions around the world. Since 1972, these devices have accurately recorded the harshness and frequency of every jounce, bump and shudder inflicted on the car on roads in the U.S., Russia, Saudi Arabia and developing markets. "Although most Malibu owners will never put their car through similar abuse, we test all new vehicles in extreme climates, inclement weather and on punishing road surfaces," said Dan Devine, Malibu validation engineer. "The 2016 Malibu is definitely up to these challenges." Tests like these ensured the current generation Malibu was dependable and durable, two qualities that in turn helped Malibu stand out from its rivals in important quality surveys, such as J.D. Power's Initial Quality Study and Vehicle Dependability Study. General Motors engineers analyze the data to calculate the precise amount of damage potholes and other hazards create over 150,000 miles. Then the conditions are replicated at GM's Milford Proving Ground in Michigan on three unique road courses, each riddled with simulated potholes of increasing severity. Engineers run preproduction cars through the course up to hundreds of times.

How GM engineers are using diaper 'snow' to keep you warm

Testing how snow affects General Motors' vehicles isn't really a problem right now for the company's engineers, but in the dog days of summer the process isn't exactly easy. The only real option is for them to book time at the automaker's climatic wind tunnel. However, a flash of brilliance from an engineer allows snow to be simulated regardless of the temperature outside, and the discovery is all because of his daughter's wet diaper. The realization came to GM Thermal Systems engineer Nicholas Jahn while he was swimming with his daughter and noticed how her diaper ballooned in size in the water. He found out the substance that makes this possible is called sodium polyacrylate. When the material gets wet it grows and forms fluffy flakes that are a close imitation of snow. Best of all, the stuff can be prepared easily any time of the year, and it's reusable. The engineering team uses the material to test the effectiveness of the heating systems of GM's vehicles. They spread the sodium polyacrylate over the inlets at the base of the windshield to obstruct the airflow and then crank the heater. After some time, they can see how much is being sucked into the system and design more efficient systems in the future. See how the process works in the video above and read about the diaper discovery in GM's press release below. Diapers Change Chevy Cruze Winter Warm-up Time GM validation engineer uses diaper material "snow" to reduce frigid drives 2015-01-06 DETROIT – An item commonly found on an infant's changing table is helping General Motors' engineers simulate snow year round, ensuring heating systems in cars like the 2015 Chevrolet Cruze can quickly and efficiently warm its interior. Packed snow can prevent air from entering the inlet panel at the bottom of the windshield, obstructing the flow of air into the heating system and reducing the amount of air it can push out. This can lead to less efficient warming of the car's interior and windshield defrosting. "The last thing anyone wants to do when it's freezing cold out is scrape their windshield," said Nicholas Jahn, GM Vehicle Thermal Systems engineer. "The testing we perform on the Chevrolet Cruze with the diaper material allows us to maximize the car's heating capabilities." Ironically, Jahn stumbled upon his diaper-based testing method in the middle of summer. During a swim with his daughter, he noticed her diaper multiplied in size when it came into contact with water.

GM investing $439 million in Corvette plant

General Motors is slowly trickling out announcements about its $5.4 billion in US plant upgrades over the next three years. The latest one is something that fans of one of America's most beloved sports car will be happy about. The Bowling Green, KY, factory that assembles the Chevrolet Corvette is receiving $439 million of those funds to build a new paint shop. Covering 450,000 square-feet, the site will make painting the 'Vette more efficient and environmentally friendly. The upgrades there include robots that use paint more effectively, technology to eliminate sludge water, LED lighting to improve inspections, and less energy-intensive baking ovens. While the groundbreaking is already complete for the building, full construction is expected to begin this summer and take two years. This is the biggest upgrade for the Kentucky factory in a few years. In preparation for the latest Corvette, the Bowling Green plant received $131 million in 2011 for upgrades and to add more workers there. Related Video: Chevrolet Corvette Plant Gets $439 Million in Upgrades New, environment-friendly paint shop drives efficient production, retains 150 jobs 2015-05-21 BOWLING GREEN, Ky. – Torch Red, Shark Gray Metallic and Laguna Blue Tintcoat, three popular palate choices on the 2015 Corvette, kept the marketers who make up names working late. Now they can dream about more painstakingly precise pigments, thanks to a new paint shop that is among $439 million being invested at the only plant in the world that builds Chevrolet's iconic sports car. General Motors announced the moves today that include retaining 150 jobs and building the 450,000 square-foot paint shop that is almost half the size of the entire current production facility. The investment builds on approximately $135 million GM has invested in the plant over the last four years for the new Corvette Stingray and Performance Build Center. The announcement was followed by a groundbreaking event for the new paint shop. "The Corvette is one of Kentucky's most-cherished icons," said. Lt. Gov. Crit Luallen. "Such a significant expansion of the Bowling Green Assembly Plant will help the company remain competitive in the region and around the world." Construction of the new paint shop, which includes substantial technology upgrades, is planned to begin this summer and take approximately two years to complete. Corvette production schedules will be unaffected by the construction.