China’s rare earth magnet export ban threatens global EV and automotive manufacturing, as US, European and Asian carmakers scramble to secure critical materials The global automotive sector is facing renewed disruption as China tightens control over exports of heavy rare earths and magnets. With EV powertrains and chips at risk, OEMs are now racing to diversify supply. Ilkhan Ozsevim
Mercedes-Benz accelerates AI and robotics at Berlin-Marienfelde, transforming digital production with humanoid robots and next-generation automation technologies At its Berlin-Marienfelde site, Mercedes-Benz is integrating artificial intelligence and humanoid robotics into automotive production. With new digital tools and axial-flux motor technology, the factory is setting new global standards for intelligent manufacturing. Ilkhan Ozsevim
JLR’s Rudy the Robot will be hard at work this Christmas in Gaydon JLR will be using an automated robot over Christmas to carry out a lifetime of door usage checks within 12 weeks, completing 84,000 door shuts. Megan Kelly
New additive manufacturing applications for the auto industry A technology that continues to develop with new materials and applications, ArcelorMittal believes additive manufacturing has clear potential in the automotive industry to optimise global platforms and extend their longevity. ArcelorMittal
Megacasting: a new frontier or unfounded flare-up for automotive production? From Tesla to Volvo, Megacasting is gaining traction. While it offers efficiency and sustainability benefits, challenges remain. Stellantis, however, remains unconvinced. 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
Ignacio Martin Gonzalez, Gestamp: “Steel is still a high-performance product” For e-mobility, suppliers like Gestamp must be willing not only to produce components, but also to contribute their expertise in terms of design. Ignacio Martin explains how the supplier is preparing for an uncertain future. Götz Fuchslocher
Exclusive: BMW Group improves efficiency with additive manufacturing gripper BMW Group has improved the speed, versatility and sustainability of its manufacturing and cut costs by using 3D-printed bionic robot grippers. Automotive Manufacturing Solutions reports on the latest innovations from the BMW Group Additive Manufacturing Campus and manufacturing plant in Munich. Megan Kelly
Mercedes-Benz has entered into an agreement to explore the use of Apptronik’s humanoid robots for its automotive manufacturing ecosystem The carmaker partners with Apptronik to integrate Apollo robots, potentially revolutionising production lines with collaborative automation, addressing labour challenges and advancing the future of automotive manufacturing. Ilkhan Ozsevim
The Centre for European Policy Studies (CEPS) publishes suggestions to stimulate demand for green steel The paper argues for stimulating demand for the green steel transition and proposes slowly phasing in ’green premiums’ so as not to upset the consumer base Ilkhan Ozsevim
Tata Steel to close two blast furnaces in Port Talbot causing major setback to regional automotive production The closures are to have a significant impact on the automotive production environment and supply chains across the region. Is the transition to green steel upsetting traditional ecosystems? Ilkhan Ozsevim
Steel resolve: why ArcelorMittal’s Multi Part Integration is leading the charge in sustainability and efficiency PARTNER CONTENTThis content was paid for by ArcelorMittal and produced in partnership with Automotive Manufacturing SolutionsFrom simplifying assembly processes to slashing carbon emissions, ArcelorMittal’s innovative approach emerges as a key player in the race towards sustainable automotive manufacturing. ArcelorMittal
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
Managing materials choices – Fossil-free steel SSAB has produced and sold its Fossil-free steel, which is now being used in limited series production by Volvo. But there is a weakness in the definition of ‘green steel’. Experts from SSAB and Volvo Group share some insights into challenges this presents to the wider acceptance of these materials and how they are managing this with greater transparency. Nick Holt
Fanuc and Volvo Cars sign deal to transform automotive manufacturing with sustainable robotics In a landmark collaboration, Fanuc, the global leader in industrial robotics, and Volvo Cars are to reshape auto manufacturing with sustainability at the forefront Ilkhan Ozsevim
Rising EV production boosts demand for more advanced automation The increase in EV demand and production is causing OEMs to look for more advanced automation, as new equipment, systems and manufacturing processes add challenges to already complex production networks, according to experts at electrification and automation supplier ABB. Megan Kelly
ArcelorMittal and Gestamp partner to enhance scrap steel utilisation in automotive manufacturing Ilkhan Ozsevim
GM and Mercedes-Benz both sign up for green steel Both General Motors (GM) and Mercedes-Benz have signed agreements for the supply of green steel for the production of their vehicles. Megan Kelly
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
BMW Group to source aluminium with reduced CO2 emissions from 2024 The company is planning to source aluminium with significantly reduced CO2 emissions from Rio Tinto’s hydro-powered operations in Canada, starting next year. Compared to conventionally manufactured aluminium, this approach can save around 70% of CO2 emissions Rebecca Morley
More than moving parts – autonomous mobile robots The fundamental changes in the type of vehicles emerging from automotive manufacturing plants worldwide most obviously the increasing proportion of electric vehicles (EVs) are also having repercussions for the development of another type of vehicle – autonomous mobile robots Mike Farish
BMW advances global plans to increase use of CO2-reduced steel The automaker expects about one third of the steel it uses to be of the CO2-reduced variety by 2026, reducing its carbon footprint by 900,000 tonnes per year, it said. Peter Murphy
Stellantis, Renault see profit in new business divisions for component re-use The initiatives aim to increase recycled content in new vehicles while establishing a closed loop for the relatively expensive and scarce minerals in EV batteries. Peter Murphy
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
Hyundai Motor and Boston Dynamics invest $400m to found robotics research institute The institute will liaise with universities and corporate research labs to create smarter and more agile robots, the institute’s executive director says. Peter Murphy
Continental to offer low-carbon biomass-based plastic for car interiors Continental said the biomass-derived PVC’s equal performance to conventional plastics makes the material a straight swap from petrochemical use but with a smaller carbon footprint in manufacturing. Peter Murphy
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
After tailpipes, auto industry ponders CO2 purge from its materials Three automotive industry executives from Polestar, Volvo Cars and SSAB discuss approaches to removing carbon from carmaking with neither a ready recipe nor time for trial and error. Peter Murphy
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
The die is cast for Volvo’s future EV production One of the key pillars of Volvo’s investment in electric vehicles will be the application of aluminium megacasting to produce large structural parts. Mikael Fermér, solution architect for vehicle platforms at Volvo Cars, explains the significance of this change for EV production. Nick Holt Christopher Ludwig
Aluminium applications Electric vehicles battery enclosures are increasing overall vehicle weight, with lightweight materials for structural components, such as castings, can offset the rise. Rio Tinto’s Jerome Fourmann tells Nick Holt about new opportunities and production innovations Nick Holt
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
Cellular manufacturing adds flexibility in Mercedes-Benz bodyshop For the production of the new C-class, Mercedes has taken the opportunity to add flexibility by way of cellular manufacturing in the body shop and with so-called ‘TecLines’ for assembly. Illya Verpraet found out more. Illya Verpraet
Non-magnetic materials for EV motors The development of electric vehicles is seeing the increasing use of materials with particular properties. Stainless steel is one example that offers applications in body structures and drivetrains Nick Holt
Thyssenkrupp restructures and carves out auto body division Thyssenkrupp has launched Automotive Body Solutions as a separate business unit to focus on both in-house production and developing lightweight materials, as well as production equipment Illya Verpraet
The time is now to start integrating robotics into plant and warehouse logistics Robotics have already enabled major productivity gains in manufacturing, but as the technology becomes more affordable and labour gets harder to find and more expensive, it could start to play a bigger role in the plant logistics and warehousing, too, helping workers do their jobs more safely and quickly. Illya Verpraet
Recycled materials in vehicle interiors While leather remains a popular material for vehicle upholstery, fabrics made from recycled materials are gaining ground. Andrew Williams looks at the latest developments and challenges Abigail Williams
Porsche and partners explore power and efficiency benefits of 3D-printed pistons Mahle and Trumpf join Porsche on a project to develop additive manufacturing processes for high-load drive components Gareth Price
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
Porsche gets comfortable with 3D-printed seat technology An innovative alternative to conventional sports seat upholstery is in development with a 3D-printed bodyform full-bucket seat Gareth Price
BMW shapes up its 3D printing prowess A new technology campus for additive manufacturing comes on stream in Munich Gareth Price
Nissan material specialists explore lightweight NVH technology Continuing its meta-material projects, the OEM has developed an acoustic barrier innovation that is 75% lighter than conventional sound insulation materials Gareth Price
Steel makes the case as the mainstay material for vehicles With OEMs demanding vehicle-structure materials that are low in mass, crash-protective and economic to use, steel grades stay true to form James Bakewell
Strong, light and formable, stainless steel re-enters the material mix Helsinki-based Outokumpu says stainless steels are ideal for lightweight, safety-critical structural parts and have put it to use in the series production of EV battery enclosures James Bakewell
Measure for measure: as vehicle tech advances, so do the test methods To improve vehicle and component quality, and reduce time to market for new models, testing technologies need to be smarter and faster Mike Farish
Breaking the mould: Grainger & Worrall go beyond the block With the onset of the EV age, casting specialists are demonstrating versatility and diversifying away from engine block production. AMS reports on the solutions Grainger & Worrall has developed to produce its new generation of cast parts Mike Farish
Material changes guide the new additive manufacturing routes Additive manufacturing is offering not only a wider range of application techniques but also materials with polymers now joined by metals and even ceramics Mike Farish
Additive from the desktop Dunlop has taken its first step into the use of additive technology with the purchase of a desktop machine Mike Farish
BMW takes additive manufacturing from prototype to serial lines OEMs and tier suppliers are now integrating additive manufacturing processes into their production operations – a prime example is BMW Mike Farish
Al around the weld Joining aluminium parts gives the bodyshop a number of challenges not encountered when welding steel. But a variety of weld techniques are helping OEMs to adapt and extend use of the lighter metal James Bakewell
Drawing attention: aluminium hot form quench Better known as a niche process for parts with deep-drawn and complex geometries in high-strength aluminium, hot form quench is now being adapted for high volume production. James Bakewell
Hot on the press The need for lightweight, high-strength steel parts has been given a boost with increased production of electric vehicles. AMS reports on a new hot stamping process designed to meet this demand Nick Holt
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
Automation advances AMS investigates how robotics can be adapted to a wider range of applications and the potential offered by 5G communications Mike Farish
A flexible solution Metal-component supplier Gestamp outlines the challenges ahead and its strategy for meeting higher demand for lightweight parts Nick Holt
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
Casting a duo Two innovative metal forming techniques could have a significant impact on the press shop of the future Mike Farish
Passing the test As modern vehicles become more sophisticated, production testing technologies and processes need to keep up. Mike Farish looks at developments with both carmakers and tier suppliers Mike Farish
Spoilt for choice Eight different models are made at DTNA’s Cleveland plant, and a high level of customisation means that thousands of options are available to customers. Michael Nash reports Michael Nash
