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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.

Toyota, Mazda form electric car technology venture

TOKYO — Toyota has established a new venture to develop electric vehicle technology with partner Mazda, seeking to catch up with rivals in an increasingly frenetic race to produce more battery-powered cars. Policymakers in key markets like China are pushing a shift to electric cars over the next two to three decades, while relatively new rival Tesla is gaining momentum and diesel cars are going through the fallout of the Volkswagen diesel scandal, pressuring traditional automakers to crank up plans for fully electric vehicles (EVs). At the same time, declining battery costs are enabling more power to be packed into cars, making an electric car future easier to imagine. Toyota said in a statement the new company will develop technology for a range of electric cars, including mini vehicles, passenger cars, SUVs and light trucks. Toyota will take a 90 percent stake in the joint venture, called EV Common Architecture Spirit Co Ltd, while Mazda and Denso Corp, Toyota's biggest supplier, will each take 5 percent. The plans build on a partnership announced in August when Japan's biggest automaker agreed to take a 5 percent stake in Mazda and two said they would jointly develop affordable electric vehicle technologies. Although Toyota is providing most of the financial firepower and existing EV know-how, Mazda's engineers have gained the admiration of the industry with breakthrough technologies such as its compression ignition engine announced last month. Shares in Mazda surged to end the day 3 percent higher, while those in Denso rose 1.8 percent. Toyota shares were flat. Both automakers are somewhat behind rivals, with neither having a fully electric passenger car on the market yet. After years of focusing on bringing hydrogen fuel cell vehicles to the market, Toyota last year set up a division to develop electric cars which is led by President Akio Toyoda, and said it plans to introduce EVs in China in the coming years. Toyota has also announced it will bring a game-changing solid-state EV battery to market by 2022. That division would continue as a separate entity from the new joint venture, a Toyota spokeswoman said, while adding that the two teams would co-operate on technology development. Mazda has an R&D budget a fraction of Toyota's, which has made it difficult to develop electric cars on its own. Even so, it has said it plans to launch EVs in 2020.

Mazda builds 1 millionth MX-5

Mazda produced its 1 millionth MX-5 Miata on April 22. Known alternately as the Miata, the Mazda Roadster, or the Eunos Roadster, the MX-5 has long held the record as the best-selling open-top two-seat sports car. It topped half a million at the turn of the millennium, and hit 800,000 less than a decade ago. The MX-5 recently entered its fourth generation over 27 years, which only promises to drive that record number higher. While it's not one of the most prolific automobiles in history – Ford has made over 34 million F-Series pickups and Toyota produced over 40 million Corollas – the Miata stands as a rather notable exception among niche performance vehicles. Related Video: Mazda Produces One-Millionth Mazda MX-5 HIROSHIMA, Japan—Mazda Motor Corporation announced today that production of the Mazda MX-5 (Mazda Roadster in Japan) reached one million units on April 22, 2016. The milestone figure was achieved over 27 years, with mass-production of the MX-5 starting at Ujina Plant No. 1 in Hiroshima in April 1989. "From the first generation through to today's fourth-generation model, the reason we have been able to continue selling the MX-5 all these years is due to the strong support of fans around the world," said Masamichi Kogai, Representative Director, President and CEO. "Mazda was founded in Hiroshima 96 years ago, and as we move toward our centennial year we will continue offering customers the joy of driving with this model, which has become a symbol of our brand. Mazda aims to create a special bond with customers and become a 'one-and-only' brand they will choose again and again." As a way of expressing thanks to MX-5 fans and owners, the One-Millionth MX-5 will be displayed at fan events in Japan and around the world. The tour begins on May 3 at the Hiroshima Flower Festival where the car will participate in the Flower Parade. The MX-5 is a symbol of Mazda's car-making philosophy and tireless pursuit of driving pleasure. Since its debut in 1989, the model has consistently offered driving fun that can only be experienced in a lightweight sports car and won the admiration of people from various countries, cultures and age groups. The MX-5 is also critically acclaimed, with over 200 awards from around the globe to its name. The fourth-generation model released last year has won a string of awards, including 2015-2016 Car of the Year Japan, World Car of the Year and World Car Design of the Year 2016.