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Toyota getting into 3D printing with i-Road in Tokyo

Think of it as Pimp My Ride for the Japanese green concept car set. Toyota is further publicizing its funky, really skinny, leaning i-Road electric concept vehicle by putting on a contest that, among other things, encourages folks to customize parts of the car's surface via 3D printing. Hey, it is a really small car. Toyota's Open Road Project in Tokyo, which will last about a year and will let about 100 participants work with 10 vehicles, also includes a component that lets contestants find the most creative parking spots by seeking out "small unused spaces with access to plug sockets" (we're sure Tokyo is full of them). What grabbed us, though, was the possibility of printing out panels for a three-wheeled car that's less than eight feet long and less than three feet wide. Earlier this year, we reported that Toyota would add five i-Road vehicles to a Tokyo carsharing pilot project. Toyota's unusual promotions for the admittedly unusual concept two-seater date back to early 2013, when the Japanese automaker featured a video of four i-Roads dancing their way through a sun-kissed Mediterranean village. Meantime, take a look at Toyota's press release below, and get more information on the project here.

Toyota R&D shows off free piston engine linear generator for future EVs

We often hear how an electric vehicle powertrain architecture allows vehicle designers much more freedom than a traditional ICE powertrain does. With differently shaped battery modules and small electric motors, there are lots of way to put the pieces together. With today's plug-in hybrid technology, engineers still need to put a decent-sized ICE somewhere, but new technology from Toyota could free up the gas-electric vehicle designers of the future. Presented at the recent SAE World Congress in Detroit, the idea from Toyota Central R&D Labs Inc. and involves what is called a Free Piston Engine Linear Generator (FPEG). Think of it as a sort of one-cylinder, two-stroke mini-engine that can work either as a generator (thank to magnets and a linear coil) or to directly drive a vehicle. The current prototype is a 10-kW unit that Toyota say would provide enough power to get a B- or C-segment electric vehicle up to highway speeds (75 miles per hour) when paired up to offer 20 kW. Pairing the FPEGs is also important to minimize vibrations. One system tested by Toyota had a 42 percent thermal efficiency, but the engineers are working to improve the overall efficiency even further. You can watch an animated video of the piston in action here (click on "Outline") and see the SAE papers here and here. More technical details are available at Green Car Congress. News Source: Toyota Labs via Green Car CongressTip: Thanks, Joe V. Green Misc. Auto Shows Toyota Technology Emerging Technologies Electric generator

Toyota spending $168 million to make more Mirai fuel cell vehicles

The last semi-official number we had for pre-orders for the 2016 Toyota Mirai fuel cell vehicle was around 200. But demand is strong enough that Toyota is saying that it will spend 20 billion yen ($168 million US) to expand annual production capacity at the "secretive workshop" where the Mirai will be built from 700 in the first year (2015) to around 2,000 after that. Japanese newspaper Nikkei reported the increase and also breaks down where Toyota expects to sell the small number of Mirai vehicles it will make in the first few years: 400 in Japan by the end of 2015, 200 or 300 In the US in 2015 (and then 3,000 by the end of 2017) and between 50 and 100 in Europe annually starting around 2016. To make all of these hydrogen cars, Toyota will add two lines to the factory where the fuel cell stacks and tanks are built and it will also upgrade the assembly location. In the US, the Mirai will initially only be sold in California next year and will start at $57,500 or lease for $499 a month for 36 months (with $3,649 due at signing). The Japanese automaker is including hydrogen fuel for "up to three years" at that price, mostly because no one knows how to accurately measure and sell H2 for cars quite yet.