Building a vehicle from scratch is a complex, expensive, and time-consuming process. According to a Jabil research, 51% of automakers are leveraging technology to make efficient and low-cost transportation a reality. Automakers have a track record of embracing latest tech developments, including innovative design and manufacturing techniques to meet ever-changing industry demands. For example, Hyundai is currently integrating software-based alternatives into car software and user experience to reduce their reliance on microchips.
Tech innovations in the automotive sector are also transforming how automakers ensure quality control. For instance, all automobile design houses are designing attractive and functional vehicles that help solve road safety, economic, and sustainability challenges. Keep reading to learn more about design and manufacturing innovations in the automotive industry.
Additive Manufacturing (3D Printing)
3D printing or additive manufacturing is becoming increasingly popular in the automobile industry. As the name suggests, additive manufacturing entails building car parts layer by thin layer until the final product is complete. This innovative process differs from subtractive manufacturing or machining that requires manufacturers to remove materials from raw deposits to design vehicle components.
There are many benefits of additive manufacturing in automobile engineering. This includes weight reduction in vehicles, fast prototyping during the research and development phase, improved customization, and waste reduction. By applying 3D printing in automobile manufacturing, automakers can produce prototypes and low-volume parts faster because there’s no tooling required. Since additive manufacturing only uses the material required for a specific component, the amount of energy used and waste produced is lower. However, sometimes producing automotive parts for some 3D printers are complex than the average, and thus desktop CNC mills are being used.
Innovative Materials for Lightweight Vehicles
Fuel efficiency has become a vital factor in determining the environmental sustainability of modern automobiles. Ideally, cars that consume less fuel have a smaller carbon footprint. To design fuel-efficient automobiles, automakers have turned to lightweight materials. It’s worth noting, a reduction of 10% vehicle weight increases fuel efficiency by 6-8%.
Emerging lightweight vehicle materials like carbon fiber, high strength steel, aluminum, magnesium, and polymer composite build light, durable, and fuel-efficient cars. Another lightweight but high strength material automakers are using in car design is titanium. Titanium sheets or plate titanium, for example, are ideal for designing outer body car panels like the roof, hood, doors, underbody panels, and decks. Compared to steel, titanium plates are lightweight and strong, thus improving the car’s safety and fuel efficiency. Titanium sheets also come in different grades, so automakers can choose sheet thickness, based on their manufacturing needs.
Use of AI in Car Production
Besides being integrated into automobile design, artificial intelligence is transforming the car manufacturing process. While robotics have been present in assembly lines for decades, they worked in defined spaces with no human interaction to promote safety. But today, robots work in shared environments with humans thanks to artificial intelligence. AI-powered robots do more than weld and paint cars. They can detect defects in materials and car components, and issue quality assurance notifications. With AI, robotics in automobile manufacturing can sense what their human co-workers are doing and adjust their movements accordingly to prevent injuries. Automobile manufacturers play a significant role in designing vehicles that provide practical solutions to current economical and environmental challenges. To achieve the best outcomes, automakers are harnessing innovative car design and manufacturing processes. Examples of design and manufacturing innovations making waves in the automotive industry are 3D printing or additive manufacturing, use of AI-powered robotics in assembly lines, and adoption of lightweight materials to design safer, durable, and fuel-efficient vehicles.