Henkel’s next-generation gap filler solutions for automotive electronics PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with Henkel.Thermal gap fillers are under greater stresses from electronic components as trends like autonomous driving take shape. AMS
Henkel’s Bergquist Liqui Form TLF 6500 CGel-SF enhances ADAS thermal performance, ensuring reliability, efficiency, and sustainability in next-generation automotive electronics PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with HenkelADAS technology demands high-performance computing, generating heat that risks system efficiency and longevity. Henkel’s Bergquist Liqui Form TLF 6500 CGel-SF provides advanced thermal management, reducing stress on components and enhancing sustainability in production. AMS
JLR and partners push seat foam circularity forward through digital tools and collaboration, accelerating sustainable material reuse in luxury vehicle production JLR’s breakthrough in seat foam circularity is powered by digital tools, data-driven traceability and production/supply chain collaboration. The Circularity Lab’s ‘learn through doing’ approach is setting new industry benchmarks for material reuse and sustainable innovation. Ilkhan Ozsevim reports. Ilkhan Ozsevim
BMW i Ventures backs Phoenix Tailings to reshape rare earth metal refining, securing a sustainable and ethical US supply chain for clean energy and manufacturing Phoenix Tailings secures funding from BMW i Ventures to scale its innovative rare earth metal refining. The milestone supports a zero-waste, zero-emission automotive future while fortifying US supply chains for clean energy and automotive production Ilkhan Ozsevim
PowerCo partners with Alterric and EnviTec to power Salzgitter Gigafactory with 3 Terawatt Hours of green energy over the next decade PowerCo SE has secured 3 terawatt hours of green electricity for its Salzgitter gigafactory through long-term agreements with Alterric and EnviTec Biogas. These partnerships will cut 115,000 tonnes of CO2 emissions annually and support Europe’s renewable energy goals. Ilkhan Ozsevim
SAMES’ solutions: precise assembly processes for battery packs PARTNER CONTENTThis content was produced by Automotive Manufacturing Solutions in partnership with SamesAs the electric vehicle (EV) market grows, the need for efficient and safe battery pack assembly intensifies. Benoit Batllo from SAMES shares how the company tackles challenges in applying critical materials like dielectric coatings, fire protection coatings, and thermal conductive adhesives (TCAs) AMS
General Motors shifts EV battery strategy by scrapping Ultium name as it balances EV ambitions with strong ICE demand The carmaker has announced it is making a strategic shift by dropping its Ultium battery branding as it reconfigures its EV business. While reaffirming its commitment to electric vehicles, GM also continues to invest in internal combustion engines to meet demand. Ilkhan Ozsevim
Hyundai, Kia, Hyundai Steel, EcoPro BM partner for LFP battery breakthroughs The Korean consortium aims to eliminate the precursor step in LFP battery cathode material production, reducing emissions and costs. The project, supported by the Korean government, focuses on developing high-purity iron powder and directly synthesised LFP cathode material for improved battery performance. Ilkhan Ozsevim
How BMW is ‘Designing for Circularity’ to become a sustainability leader in automotive production BMW’s Roberto Rossetti, Total Vehicle Life Cycle Development, elucidates BMW’s innovative ’Design for Circularity’ approach. From using recycled materials to optimising vehicle disassembly, BMW is redefining how vehicles are produced and consumed. Ilkhan Ozsevim
Reinventing the wheel: the race towards sustainable tyre production Nokian Tyres is building the world’s first zero-carbon tyre factory, with Michelin, Continental, Bridgestone, and Pirelli leading the charge with recycled materials, bio-based components, and innovative sustainable production methods. Ilkhan Ozsevim
GM and Samsung SDI seal $3.5B deal for Indiana Electric Vehicle battery plant General Motors and Samsung SDI have cemented a $3.5 billion agreement to establish an advanced EV battery manufacturing plant in Indiana. This facility will enhance GM’s EV production capabilities by delivering up to 36 GWh of prismatic battery cells annually. Ilkhan Ozsevim
Korea’s LG, SK On and Samsung lead Prismatic battery revival impacting Electric Vehicles and Automotive Production The prismatic battery is making a comeback, with Korean battery giants leading the charge. Offering advantages in safety and cost, this technology could have lasting implications for the Electric Vehicle, battery, and automotive production landscape. Ilkhan Ozsevim
Unipart strengthens UK lightweighting production expertise with polymer and composite solutions for automotive production Unipart expands its automotive capabilities with the acquisition of Formaplex, creating Unipart Polymer and Composite Solutions. The deal enhances the company’s lightweighting expertise, supporting the transition to electric vehicles. Ilkhan Ozsevim
Stryten Energy and Dragonfly Energy agree to electrify North American automotive production A strategic partnership between Stryten Energy and Dragonfly Energy will see the ’Battle Born Batteries’ brand enter new consumer markets, while bolstering domestic lithium battery production. Ilkhan Ozsevim
Powering the future: Top 5 EV battery chemistries and formats across the world With batteries underpinning the electrification journey, we take a look at the battery chemistries and architectures driving the change. AMS
How Ford’s Marc Dugas is supercharging battery pack assembly using the POSIWID system In this Q&A we explore how Marc Dugas, Ford’s Technical Specialist for Battery Pack assembly, uses a little-known systems thinking heuristic called POSIWID, (the Purpose Of the System Is What It Does) to supercharge battery pack assembly Ilkhan Ozsevim
Changing dynamics– developing the next generation of vehicle architectures Building electric vehicles has demanded big changes in OEM production operations and increased support from tier suppliers. Gestamp’s director of R&D North America, Paul Belanger, shares some insights into the company’s development and how it’s managing the engineering challenges around EVs Nick Holt
The co-evolution of EVs, architectures and production processes Electric vehicles and batteries are influencing automotive manufacturing decisions, driving changes in vehicle architectures, production processes and material choices. Gestamp and ArcelorMittal discuss their strategies Ilkhan Ozsevim
Is sodium-ion the future of battery tech? - Stellantis Ventures all-in on France-based battery tech startup, Tiamat The battle of battery tech continues. Stellantis is investing in Tiamat’s sodium-ion tech, eyeing cost-effective, sustainable energy, while, BMW pursues Solid Power’s solid-state batteries for efficiency gains. Which chemical composition will lead? Will any? Ilkhan Ozsevim
The state and stipulation of automotive production: Retrospect 2023 to prospect 2024 Using 2023 as a launchpad into the coming trends of 2024, we take a dive into the coming automotive production trends set to shape the industry Ilkhan Ozsevim
The automotive value-add of additive manufacturing and simulation technologies: an agile and resilient powerhouse in engine development Markforged’s additive manufacturing solves Punch Torino’s automotive challenges with robust camshaft tools. Simulation technology streamlines design, reducing iterations with a future focus on sustainable internal combustion engines and alternative fuels. Ilkhan Ozsevim
New materials drive electric motor development Original equipment manufacturers need electric motors that are more energy-efficient and power-dense than those currently available. How composites and resin materials could support developments on this area was discussed by industry experts at a recent conference organised by Sumitomo Bakelite Europe (Ghent) NV (Sumitomo Bakelite Ghent). James Bakewell
Ionway: Volkswagen Group’s PowerCo and Umicore establish new European battery materials JV in Nysa, Poland JV a tactical convergence between the OEM with major battery materials player effectively pooling resources and expertise to capitalise on European market as demand booms Ilkhan Ozsevim
Battery production and design need to be optimised together, says Volvo Trucks and ABB Václav Švub from ABB Robotics and Wenting Hu from Volvo Trucks pointed to the benefits of aligning battery engineering and production processes in an exclusive AMS livestream, including opportunities in automation, new materials and production processes. Ilkhan Ozsevim
Ford partners with EcoPro BM and SK On to build cathode plant in North America bolstering EV SC in region The facility will produce Nickel Cobalt Manganese cathode active materials for Ford’s future EVs and produce up to 45,000 tonnes of CAM per year. Ilkhan Ozsevim
GM announces $60m Series B investment in AI-powered battery materials trailblazer Mitra Chem Mitra Chem uses AI to develop iron-based cathode materials for lithium-ion batteries in reduced time to market and may signal GMs exploration of alternative battery materials to thwart ongoing supply shortages. Ilkhan Ozsevim
Shaping the future – Developing electric vehicle architectures In our AMS Evolution Livestream experts from ArcelorMittal and Gestamp tackle EV production challenges and explain how digital tools, new technologies, processes and materials innovations could help solve some key issues Michael Nash
Re-evaluating recycled materials Carmakers are increasingly looking into ways of reducing the environmental impact of their vehicle manufacture – and one way to do this is by using more recycled materials in their cars. But how can they go about this? James Bakewell
Magna to build new battery enclosures facility in Canada to support Ford F-150 Lightning production The company will also manufacture battery enclosures for GM’s Silverado EV in St. Clair, Michigan, adding to existing battery enclosure production for the Hummer EV Rebecca Morley
Mercedes looks to chemical recycling to further develop circular manufacturing operations Mercedes-Benz is working with BASF and start-up Pyrum Innovations to develop and utilise chemical recycling that will enable circular manufacturing of virgin-quality plastics for vehicle components AMS
3D printing: a step closer to mainstream production Additive manufacturing technologies are now established as useful tools right across the automotive manufacturing sector. But inhibiting factors to their increased adoption include both their limitations in volume applications and a more misplaced perception that they cannot make highly robust parts Mike Farish
Watch: New magic in the dark art of lightweighting Ignacio, Jérôme and Prof. Volk explain the magic behind the art of lighweighting all whilst factoring in cost, performance, safety concerns and the impact on manufacturing process. Nick Holt
Megacasting: a chance to rethink body manufacturing The aluminium die-casting process could revolutionise body construction. Professor Wolfram Volk, the department head for forming technology and casting at the Technical University of Munich, explains the advantages and disadvantages of so-called ‘mega’- or ‘gigacasting’. Götz Fuchslocher
Stress test: new modelling approach for component fatigue testing The development of lightweight structures and components for electric vehicles has created a demand for more comprehensive and up to date test and measurement processes to evaluate component fatigue and service life. Nick Holt spoke with Lucia Barbu, research professor and project coordinator at Fatigue4light to get some insight into the challenges and solutions Nick Holt
Thinking outside the box: lightweight battery enclosures The lightweighting of electric vehicle (EV) structures is a key element in helping to extend the endurance ranges necessary to accelerate their increasing adoption. A specific target for weight reduction is the compartment used to house the batteries Mike Farish
Building the battery pack While cell manufacture is still largely in the realm of specialist producers, more OEMs are now assembling the battery pack inhouse, but this can be a complex task requiring specialist tooling. Nick Holt reports Nick Holt
Power is nothing without control Chassis components keep the wheels from falling off the EV revolution. Illya Verpraet found out how Gestamp is managing the change with material and quality control innovation Illya Verpraet
Composite case study: curved rear bumper beam of the Corvette Stingray Performance vehicle structures have long made extensive use of composite materials and the new generation of GM’s flagship sportscar, the Chevrolet Corvette Stingray, continues the push. A key composite component of the new Corvette Stingray is a curved carbon fibre rear bumper beam, created through a bespoke application of radius pultrusion… Gareth Price
Bloodhound’s additive challenge Advances in additive manufacturing are being put to the most stringent of tests as the Bloodhound Land Speed Record project makes its first high-speed runs. Chris Pickering speaks to the engineers behind the project and the contribution made by 3D-printed components, one of the key production technologies helping to make the attempt possible Chris Pickering
Creating strong bonds While mixed-material vehicle body structures yield impressive weight reduction results, the joining processes present a challenge for OEMs. How do they fix the myriad materials but still maintain the requisite properties and structural integrity? James Bakewell
Conference: Insight @ BMW For its latest North American car body engineering Insight conference, the Automotive Circle heads to upstate South Carolina – a region that’s home to the largest plant in the BMW manufacturing network… Gareth Price
Collective thinking Michael Nash and Closer collaboration between product development and production teams could lead to significant improvements in vehicle manufacturing processes. Ford Otosan holds a unique position. Michael Nash reports
The case for carbon fibre The launch of the i3 has changed the conversation about the future application of carbon fibre in vehicle structures James Bakewell
