With GPS data from as little as 6% of vehicles on the road, University of Michigan researchers can recalibrate traffic signals to significantly reduce congestion and delays at intersections.In an 18-month pilot study conducted in Birmingham, Michigan, the team used connected vehicle data insights provided by General Motors to test its system, resulting in a 20% to 30% decrease in the number of stops at signalized intersections. GM vehicles make up 6-10% of cars currently on the road in the United States.Officially, it’s the world’s first large-scale, cloud-based traffic signal retiming system, and it represents a major opportunity for communities to recalibrate their signal patterns at a reduced cost. U-M’s research appears in Nature Communications.The U-M system takes GPS data from a percentage of vehicles on the road and extrapolates traffic patterns. For example, a connected vehicle that comes to a stop roughly 100 feet from an intersection strongly indicates that it is behind at least three or four other vehicles.<iframe width="640" height="360" src="https://www.youtube.com/embed/gb2iAR_bAwc?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>“While detectors at intersections can provide traffic count and estimated speed, access to vehicle trajectory information, even at low penetration rates, provides more valuable data including vehicle delay, number of stops and route selection,” said <a href="https://cee.engin.umich.edu/people/liu-henry/" target="_blank">Henry Liu</a>, U-M professor of civil engineering and director of both Mcity and the Center for Connected and Automated Transportation.There are roughly 320,000 traffic signals in the U.S. and the annual congestion costs—direct and indirect—associated with those intersections comes out to $22.9 billion. Those costs include time spent waiting at lights, as well as unnecessary energy consumption caused by signal times that can be improved.Most traffic signals operate on a time-of-day signal timing plan, where preset patterns are in place for morning, afternoon, evening and overnight. Traffic planners attempt to coordinate those cycles with surrounding intersections to allow cars to flow between intersections with as little stop-and-go travel as possible.“The reason these signals should be changed more often is that traffic is always changing,” Liu said. “A good example is the traffic patterns we saw in the year before COVID’s arrival and the two years afterward. Your morning peak hour changed drastically with so many people working from home. When you see that kind of change you need to retime these signals.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713181677025-close-up-traffic-visual-1280x852.jpg" style="width: 100%px;" class="fr-fic fr-dib">Xingmin Wang, CEE Research Fellow and Adjunct Lecturer, looks over a visualization of vehicle trajectory data in Ann Arbor, MI on November 30, 2023.Optimizing signals to keep up with changes in traffic flows isn’t a simple task. The costs and time involved in doing traffic counts and recalculation mean most municipalities won’t reassess for two to five years, or sometimes decades.While adaptive signals have been around since the 1970s, detecting vehicles at intersections to reprogram signals almost in real time, cost has kept them from widespread use. Installation of an adaptive system at a single intersection can cost as much as $50,000, with regular maintenance required—a price tag not all communities can afford. The U-M system for optimization would cost a fraction of that for an adaptive system.The U-M system, called a probabilistic time-space diagram, allows for a smaller percentage of connected vehicle data to do the same workload as sensors at an adaptive traffic signal. To test its effectiveness, researchers collected data over the course of three weeks in March 2022 from each of Birmingham’s 34 signalized intersections—most of which are fixed-time systems.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713181694618-inside-traffic-signal.jpg" style="width: 100%px;" class="fr-fic fr-dib">Mcity Test Facilities Manager, Jim Lollar, looks inside a traffic signal cabinet at Mcity on Thursday, November 30, 2023.“What this has done is really solve our data collection issue,” said Gary Piotrowicz, deputy managing director of the Road Commission for Oakland County. “And I could argue that this is going to be the way everybody in the country does it. Once they’ve solidified the system, there’s no reason to do it any other way.”Liu’s team features several graduate students including Zachary Jerome, a graduate research assistant and member of the&nbsp;<a href="https://traffic.engin.umich.edu/home" target="_blank" rel="noreferrer noopener">Michigan Traffic Lab</a> who helped develop U-M’s algorithm. Jerome worked directly with RCOC and hopes to collaborate with industry partners to help other municipalities deploy this cost-saving technology.&nbsp;“The opportunity to work with industry to bring this groundbreaking technology into real-world applications is incredibly inspiring,” Jerome said. “My vision is that this system will provide a revolutionary signal retiming solution for communities across the world that is scalable, sustainable and efficient.”

Communities could reduce costs and cut vehicle emissions—all in the name of shortening your trip.

Improving traffic signal timing with a handful of connected vehicles

Even among people who never miss their yearly medical checkup, very few undergo regular brain examinations. CT scans or magnetic resonance imaging (MRI), which provide a direct view of the state of the brain, utilize equipment that is large, expensive, and requires a high level of specialized expertise in addition to medical knowledge to operate safely. As a result, such examinations are only available at large medical institutions.Murata Manufacturing (Murata) has developed a technology that has the potential to enable ultrasonic scans, which are presently used to view the fetus within the uterus, to be used to view the brain within the cranium. It may be possible, by placing a sheet with a unique structure called an “ultrasound transmission metamaterial” on the skin of the patient’s head, to make the cranium transmissive to ultrasonic waves. If this can be achieved, it is possible that a wider range of medical institutions will be able to perform examinations of the brain relatively easily.Potential fields of application for ultrasound transmission metamaterial are not limited to medicine. In a variety of different areas, such as making automobiles “smarter” and the maintenance and management of social infrastructure, this new technology has the potential to encourage wider utilization of ultrasonic waves. Murata exhibited the ultrasound transmission metamaterial at CEATEC 2023, held at Makuhari Messe from October 17 to 20, 2023. We interviewed Mr. Nishida and Mr. Hussain of the Material Technology Sensor Material Process Development Department, Technology &amp; Business Development Unit of Murata Manufacturing, who were involved in the development of the new technology, about the operating principle behind its unique functionality, as well as possible applications.<h2>Ultrasonic sensors have many useful characteristics, but they can’t detect objects on the other side of a barrier</h2>--What sorts of things does the technology behind the ultrasound transmission metamaterial make possible?Nishida:&nbsp;An ultrasound transmission metamaterial is a material that makes obstructions, which would otherwise prevent ultrasonic waves from passing through, transmissive. As used here, the term “metamaterial” refers to a man-made substance that has functionality for realizing behavior not seen in the natural world, with respect to the propagation of waves of magnetism or sound.Ultrasonic waves are sound waves with a frequency beyond the audible range of the human ear (20 kHz and above). They are used in a variety of areas, ranging from industrial and medical devices to home appliances. Many applications are products that most people will be familiar with, such as fishfinders, ultrasonic cleaners for eyeglasses, and ultrasonic humidifiers. When employed as a sensing medium, ultrasonic waves can be used to detect transparent solid or liquid items or small objects in dark places as well as objects with low reflectance of radio waves. In recent years, ultrasonic sensors have also come into use in automated car parking systems.Ultrasonic waves can be used for many different applications, but one thing limiting the range of uses is that they are unable to pass through barriers made of materials such as metal or resin to reach objects on the other side. When ultrasonic waves impinge on a substance with an acoustic impedance significantly different from that of the propagation medium (air when detecting objects in the atmosphere), most of them are reflected back and very few pass through. “Acoustic impedance” is an index of how easy it is for sound to be conveyed. It is a small value in the case of air, in which molecules are distributed thinly, and a high value in the case of dense substances such as metal or resin. This is why the boundary between air and a solid barrier is not transmissive to ultrasonic waves.&nbsp; Note: For a detailed description of “acoustic impedance,” click <a href="https://www.murata.com/en-eu/products/sensor/ultrasonic/overview/basic/nature?intcid1=mar_art_xxx_tac_xxx_tac-ows" target="_blank">here</a>.The ultrasound transmission metamaterial developed by Murata incorporates a resonating mechanism utilizing a spring-mass resonator structure. Placed on top of the material constituting the obstruction, it reduces the difference in acoustic impedance, thereby increasing the transmissivity to ultrasonic waves.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNzYxNTk3OTYwLWltZzAwMDFhLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Ultrasound transmission metamaterial that enables ultrasonic waves to pass through substances</h2>--Specifically, what functionality did you achieve when you created a prototype of the ultrasound transmission metamaterial?Hussain:&nbsp;The structure of the ultrasound transmission metamaterial developed by Murata consists of “tiny unit cells,” each composed of a weight and a spring, arrayed regularly on a backing sheet (Figure 1). It is designed so that, by adjusting the configuration and size of the weights and springs, the unit cells can act as spring-mass resonators when impinged upon by ultrasonic waves. The unit cells resonate perpendicularly to the direction of the impinging ultrasonic waves, causing an obstruction with a greatly different acoustic impedance to become transmissive and allowing the ultrasonic waves to propagate efficiently.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNzYxNjMxOTI4LWltZzAwMDJiLWVuLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">Figure 1: Figure showing how the prototype of “ultrasound transmission metamaterial” created by Murata increases ultrasonic permeability and schematic diagram of unit cellTo create the prototype, a 3D printer was used to form tiny unit cells on a stainless steel plate 1 mm thick. This was then immersed in water and ultrasonic waves at a frequency of 500 kHz were directed toward it from a transmitter. The receiver on the other side indicated that we had succeeded in achieving 60% ultrasonic transmissivity. This technology can enable ultrasonic waves to pass through more than just stainless steel plates. It can be applied to a variety of different materials if we can design unit cells matched to the difference in acoustic impedance between the obstruction and the transmission medium.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNzYxNjU1ODUyLWltZzAwMDMuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Prototype and test rig during verification of effectiveness<h2 id="isPasted">Using an ultrasonic scan to examine a brain encased in the cranium</h2>--What sorts of applications do you envision for the ultrasound transmission metamaterial you have developed?Nishida:&nbsp;First of all, we envision its application as a material used in medical examinations. In the medical field, ultrasonic scans are used as an examination method to reveal important information that cannot be obtained using X-ray, CT, or MRI scans. A particular advantage of ultrasound scans is that they produce video output showing the movement of the affected part of the body. In addition, unlike examination method such as CT scans that employ X-rays, there is no danger of overexposure to radiation.<figure><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNzYxNzMyNTYwLTE3MTI3NjE3MzI1NjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="601" height="539" alt="Image of using an ultrasonic scan to examine a brain encased in the cranium" class="fr-fic fr-dii"><figcaption> </figcaption></figure>But even though ultrasonic scans provide these benefits, ultrasonic waves are not able to pass through bone and can therefore not be used to examine organs or structures that are encased in bone. This means that ultrasonic scans cannot be used to examine the brain, which is encased in the cranium.The ultrasound transmission metamaterial may make it possible to perform ultrasonic scans of the brain. It is our hope that this will enable detailed examinations to be performed easily, even at smaller medical facilities, while minimizing the burden on the patient.<h2>Installing ultrasonic sensors without detracting from the design attractiveness of automobiles</h2>Hussain:&nbsp;Ultrasonic sensors are used in automotive parking-assist systems, but our new technology will make it possible for them to be installed in places where they are not exposed on the outside of the vehicle. Up to now, it has been necessary to install automotive ultrasonic sensors on the exterior surface of the vehicle’s body. If they are under a cover of some kind, the ultrasonic waves are not able to pass through.<figure><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNzYxNzMyNTE5LTE3MTI3NjE3MzI1MTkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="600" height="377" alt="Image of installing ultrasonic sensors without detracting from the design attractiveness of automobiles" class="fr-fic fr-dii"><figcaption> </figcaption></figure>There is no doubt that in the near future automobiles will need to have many different kinds of sensors installed in various places on the vehicle in order to enable autonomous driving functionality. It is possible that for many consumers who love cars, the value as products of models with a large number of unsightly exposed sensors on them will drop. Also, installing the sensors in exposed positions on the body reduces their durability. For this reason, there is demand for technology that will enable ultrasonic sensors to be installed in a way that does not detract from cosmetic appearance or reliability. By using an ultrasound transmission metamaterial, it will become possible to install ultrasonic sensors in places like inside a car’s bumpers.<h2 id="isPasted">Noncontact inspection of the interior portion of underwater cables within the cladding</h2>Nishida:&nbsp;The technology can also be applied in the maintenance and management of underwater cables used for things like long-distance communication and offshore wind power generation. Maintenance and management to ensure the stable operation of underwater cables requires inspection not only of the exterior, but also of the interior portion of the cable inside the cladding. Nevertheless, up to now, there has been no way to check the status of the interior of cables encased in cladding.<figure><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEyNzYxODA2MzE5LTE3MTI3NjE4MDYzMTkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="600" height="531" alt="Image of enabling noncontact ultrasonic inspection" class="fr-fic fr-dii"><figcaption id="isPasted">Enabling noncontact ultrasonic inspection</figcaption><figcaption> </figcaption></figure>Adding an ultrasound transmission metamaterial to the cladding of underwater cables would make it possible to inspect the cable interior without making physical contact, by using underwater drones equipped with ultrasonic sensors or by lowering such sensors from ships. This has the potential to reduce the burden associated with inspections of underwater objects in seas or rivers.<h2>Ultrasound transmission metamaterial that expands the range of places where ultrasonic waves can be used</h2>Hussain:&nbsp;In the businesses involved in implementing the newly developed technology in society, I hope we can create a system enabling the design of unit cells optimized for places where ultrasound transmission metamaterials are used, and complete and make available solutions that provide the required results.Nishida:&nbsp;The three application examples we have described are only some of the candidates we can envision at this point in time. The unique technological characteristics of ultrasound transmission metamaterial will surely expand the range of places where ultrasonic waves can be used and pave the way for many more applications we haven’t even thought of yet. In addition to sensors, applications using ultrasonic waves to process or clean materials may give rise to additional value in the application of the technology we developed.We still have a lot of work to do refining the new technology for use in actual applications. At the same time, we are working to pave the way for innovative new applications and to attract a wide array of business partners to help with the refinements. If you think your company would be interested in joining us in this effort, please feel free to contact us.<hr id="isPasted"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1713769861492-1713769861492.png" class="fr-fic fr-dii">If you have any questions based on this article that you would like to discuss with an expert at Murata, don't hesitate to reach out. There's an entire team ready to support you with your question.<a href="https://www.murata.com/en-eu/contactform?&Detail=Wevolver%20request" target="_blank" rel="nofollow" class="button-main-action">GET IN TOUCH</a>

Murata Manufacturing (Murata) has developed a technology that has the potential to enable ultrasonic scans, which are presently used to view the fetus within the uterus, to be used to view the brain within the cranium.

"Ultrasound Transmission Metamaterial" that Expands the Range of Places where Ultrasonic Sensors Can Be Used to Include Medicine and Automobiles

What’s the extent of impact of electric vehicle on drivetrain system? Electric Vehicle is driving significant change in drivetrain design for electric vehicles, with the use of different kinds of automatic transmissions and integrated units to optimize efficiency. Despite differences in operating principles, there are similarities. Explore the impact and challenges of drivetrain design and find how RPWORLD comes in to accelerate the design iteration.<h2 dir="ltr">What’s the Impact of EV on Drivetrain Design</h2>Electric Vehicle is driving significant change in the way manufacturers approach drivetrain design, as compared to the development process for traditional combustion engine vehicles. This change is reflected in the use of different kinds of automatic transmissions, such as 2-stage spur gear drives, integrated stepped planetary gear drives, or continuously variable transmissions (CVT), to optimize efficiency in state-of-the-art electric vehicles, whereas previously 6-speed manual or 8-speed automatic transmissions were standard in the automotive world.One notable difference is that electric motors, power electronics, and drivetrains can share a single housing, which reduces the overall number of components in the powertrain and lowers the system's weight. In battery electric vehicles (BEVs), this integrated unit may directly power a combined electric axle drive, while various transmission configurations are possible in hybrid vehicles, depending on how the manufacturer intends the electric motor and combustion engine to interact with each other.<h2 dir="ltr">Challenges in Component Design for Electric Vehicle Drivetrains</h2>Despite the differences in operating principles between electric vehicle drivetrains and their combustion engine counterparts, there are many similarities in the design and manufacturing processes required at the component level. Key components such as straight gears, helical gears, and housings are common to both types of drivetrains. However, specializing such components for electric vehicle drivetrains presents challenges in dealing with the higher torque and speed of rotations that can be achieved with electric motors.<ul><li><h3 dir="ltr">Special considerations for precision manufacturing</h3></li></ul>The precision manufacturing of transmission components like straight and helical gears or planetary gear drive systems requires tighter tolerances for electric vehicle components. The surface finish of gears also gains new importance as the noise emission of the drivetrain is critical in electric vehicles due to the silent electric motor.<ul><li dir="ltr"><h3>Shift in drivetrain design</h3></li></ul>Electric Vehicle is driving a significant shift in drivetrain design for state-of-the-art electric vehicles, leading to the use of different kinds of automatic transmissions and integrated units that reduce the overall number of components and weight of the system. Despite differences in operating principles, there are many similarities in the design and manufacturing processes required at the component level. Specializing components for electric vehicle drivetrains requires dealing with higher torque and speed of rotations and tighter tolerances, as well as placing greater importance on surface finish to reduce noise emission from the silent electric motor.<h2 dir="ltr">Customized Drivetrain Components to Meet Your Specific Needs</h2>At RPWORLD, we understand that every vehicle's drivetrain requirement is different, and that's why we offer customized drivetrain components with tight tolerance and high efficiency to meet your specific needs. Our 20-years’ experience in manufacturing allows you to turn your design into reality fast and accelerate your iteration and prototyping verification.RPWORLD is a customized manufacturing supplier, offering CNC Machining, Injection Molding, Sheet Metal Fabrication, Surface Treatment and more.

Photo by ThisisEngineering RAEng on Unsplash

Explore the impact and challenges of drivetrain design and find how RPWORLD comes in to accelerate the design iteration.

Customized Drivetrain Components: Meeting the Challenges of EV Design

At A GlanceChallengeInjection moulding 210 parts in 5 weeks for the battery pack cooling system for a fully electric super sports car prototypeSolutionHutchinson relied on Protolabs to obtain three different components within the required time and with the prescribed quality. The speed of interaction between Hutchinson and Protolabs, combined with experience in the automotive sector, allowed for the production of 210 parts in less than 5 weeks from the first contact.OutcomeThe iteration speed of Protolabs and Hutchinson led to perfect parts being delivered on time, ready to be tested and installed on the supercar prototype, reducing validation and testing times.<hr> In June 2023, 138,937 new cars were registered in Italy. Of these, just under 10% were electric cars: 7,539 plug-in hybrids and 6,159 fully electric vehicles. Adding the remarkable figure of 48,937 new electric hybrids, electric and hybrid cars together accounted for almost 45% of new registrations. &nbsp; <a href="https://www.hutchinson.com/en" target="_blank">Hutchinson</a>, a Total Group subsidiary, is a French multinational with 38,000 employees across more than 100 industrial sites in 25 countries, specialising in designing and manufacturing polymer-based products and systems for fluid management. Located in Rivoli, near Turin, is the global centre of competence for automotive fuel systems, typically for diesel or gasoline vehicles. However, in electric cars, such a system is non-existent. Instead, a similarly crucial component for the proper functioning of electric cars is the battery pack temperature stabilisation system, a critical node for vehicle safety. &nbsp; In 2025, Italy will introduce a fully electric supercar, and work on prototype development has already begun, thanks to the collaboration between <a href="https://www.protolabs.com/en-gb/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-automotive-0124&utm_content=wevolver-hutchinson-cs-0324" target="_blank" rel="noopener noreferrer">Protolabs</a> and Hutchinson.Designing a supercar means thinking big, and Engineer Valter Mondini, Project Manager, understands that no detail can be left to chance in a project of such significance. Hutchinson was brought in to find the best solution for cooling the battery pack. For a car to be defined as a supercar, it must deliver exceptional performance in speed and range, the latter being determined by a battery pack as extensive as possible while minimising space for other elements.The main technological challenge was minimising the space the hydraulic system used to cool the battery pack took. This involved replacing the&nbsp;<a href="https://www.protolabs.com/en-gb/materials/?utm_source=eureka&utm_medium=referral&utm_campaign=uk-automotive-0124&utm_content=eureka-spotlight-hutchinson-cs-0124" target="_blank" title="Materials">material</a> used to make the tubes. Initially, the tubes were made of rubber that contained water and glycol, but Protolabs replaced the material with extruded plastic, ensuring the same mechanical performance. Each piece had to be flawless to guarantee a seal of up to 4 Bar. It was crucial to avoid any moulding imperfections, such as burrs, as they could mark the tube during the cold fitting phase and compromise the hydraulic system's seal.<img border="0" width="359" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwOTM3MTk2MTMyLTE3MTA5MzcxOTYxMzIuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="Protolabs and Hutchinson collaborate on the first Italian electric supercar" class="fr-fic fr-dii" style="width: 451px;">"Protolabs is among Hutchinson's accredited suppliers and collaborates on projects where the speed of iteration and the quality of the products obtained are unparalleled. They accepted the challenge. The timelines were extremely tight: we needed to produce four different&nbsp;<a href="https://www.protolabs.com/en-gb/services/injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-automotive-0124&utm_content=wevolver-hutchinson-cs-0324" target="_blank" title="Injection Moulding" rel="noopener noreferrer">injection-moulded</a> components in the specified material, with particularly tight tolerances given the importance of the battery cooling hydraulic system. Given the project's significance," explains Engineer Mondini of Hutchinson, we could not afford any mistakes.<blockquote>"Protolabs is among Hutchinson's accredited suppliers and collaborates on projects where the speed of iteration and the quality of the products obtained are unparalleled. They accepted the challenge." V. Mondini, Project Manager &amp; Engineer at Hutchinson</blockquote>&nbsp;"Upon receiving the initial request from Hutchinson," explains Stefano Mosca, Senior Account Manager at Protolabs in Italy, "we immediately involved our injection moulding centre of excellence in Eschenlohe, which is particularly accustomed to responding to requests from the automotive sector. We were already familiar with the sector's required standards and knew that when we are involved in a project, it is primarily for the speed and quality assurance of the parts we produce. In 5 weeks, we validated the project, produced the moulds, chose the filler percentage of both Nylon and PPS together with the customer, injected moulded the parts, and shipped them."The project is a fine example of international collaboration. The development project for these components was undertaken in Italy, developed in France, produced in Germany, tested in Italy, and a portion of the parts was shipped from Protolabs to Poland to be mounted on some prototypes— a fitting example of how an international supercar, which will be sold worldwide, is born.<img border="0" width="295" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzEwOTM3MTk2MTM5LTE3MTA5MzcxOTYxMzkuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" alt="A close-up of several pipesDescription automatically generated" class="fr-fic fr-dii" style="width: 370px;">&nbsp;&nbsp;About Hutchinson:Hutchinson designs and manufactures smart solutions for a world on the move and contributes to future mobility on land, in the air and at sea. With expertise in fluid transfer, sealing, anti-vibration systems and materials &amp; structures, Hutchinson is a global leader in&nbsp;developing innovative solutions for sustainable mobility.To find out more, visit the&nbsp;<a href="https://www.hutchinson.com/en/accueil" target="_blank">Hutchinson</a> website.

Designing components for a super car means thinking big, delivering exceptional performance, and executing a flawless design.  Learn how Hutchinson worked with Protolabs to injection mould a battery pack cooling system in just 5 weeks.



Protolabs and Hutchinson collaborate on the first Italian electric supercar

<h2 id="isPasted">Insights into the Inspection Challenges Arising during Sheet Metal Manufacturing.</h2>Manufacturing sheet metal is far from a simple task. It requires rigorous inspection, primarily due to the high quality and stringent safety standards required in the automotive industry. No doubt, a combination of advanced technology and skilled labor must be involved to ensure that the sheet metal components are cut and shaped to precise dimensions. This includes checking for correct length, width, surface profile, and overall shape. Quality inspection is vital because automotive sheet metal must withstand stress and fatigue over the vehicle’s lifetime.Apart from ensuring safety, quality inspection also ensures that the visual standards of consumers are met. This is achieved by guaranteeing that parts are assembled with the best possible flush (height on either side of a gap) and the smallest gap (width of a strip between two car components, e.g. door and chassis).This blog post addresses the inspection challenges involved in sheet metal manufacturing. If you are looking to enhance the quality of your sheet metal parts, balance the thoroughness of inspections with cost and time efficiency, and gain some tips that could give you an edge over your competitors, this article might pique your interest.<h2>The Most Popular Manufacturing Techniques for Sheet Metal</h2>Stamping and laser cutting are among the most commonly used methods for manufacturing sheet metal components in the automotive industry. Both techniques require some level of dimensional inspection, ensuring that parts meet specified dimensions and tolerances. However, the extent and nature of the inspection vary depending on the process used.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817909876-Industrial-press-for-sheet-metal-stamping-and-CNC-laser-machine-cutting-sheet-metal-1536x507.webp" style="width: 100%px;" class="fr-fic fr-dib">CNC laser machine cutting sheet metal with light spark. Technology plasma industrial, Blue steel color.<h3 id="isPasted">Stamping</h3>Stamping involves using a stamping press to transform flat sheet metal (in either blank or coil form) into a net shape. This method is used to manufacture high-volume parts like frames, hoods, doors, and panels. Dimensional inspection is crucial in this process due to the high volume and precision required for these automotive parts. Inspections typically focus on checking the dimensions of features like holes, flanges, and bends, as well as overall part geometry.<h3>Laser Cutting</h3>Laser cutting, on the other hand, is used for cutting precise shapes in metal. It is typically used to produce intricate components or those that require a high degree of accuracy. Precision is key in laser cutting, so inspection typically focuses on the accuracy of cut dimensions, edge quality, and the position of features like holes or cutouts.In each of these techniques, various tools and instruments can be used for dimensional inspection, such as traditional calipers and micrometers, coordinate measuring machines (CMMs), or laser scanning and 3D metrology tools. The choice of measuring equipment depends on the complexity of the parts, the precision required, and the production volume.Laser 3D scanning is particularly advantageous for inspecting parts with complex shapes and detailed features or when high precision is required. Its ability to quickly capture a part’s entire geometry in high detail makes it a valuable tool, particularly for sheet metal manufacturing.<h2>What to Inspect on a Sheet Metal Part</h2>On sheet metal, certain features and dimensions are particularly critical to inspect due to their importance in the structural integrity and functionality of the part. Moreover, some bends or curved areas are often challenging to form and are prone to issues like spring back or deformation. Hence, manufacturers must control the quality of their parts, particularly the overall shape and edges.<h2>Keys Points for Controlling the Overall Shape</h2>Objective: Detecting any warping or distortion that might have occurred during manufacturing.While common, regular shape control involves a flatness tolerance, the inspection of complex 3D geometries involves a profile of a surface (or surface profile) tolerance.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817936809-GDT-in-VXinspect_Sheet-Metal-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib">Mockup image of a businesswoman using laptop with blank white desktop screen with coffee cup on wooden table in cafe<h3 id="isPasted">Flatness</h3>Symbolized by a parallelogram in GD&amp;T, a flatness tolerance specifies a tolerance zone defined by two parallel planes within which the surface or derived median plane must lie.<h3>Profile of a surface</h3>Represented by a half-circle in GD&amp;T, the tolerance zone established by the profile of a surface tolerance is 3D (a volume), extending along the length and width (or circumference) of the considered features.The profile of a surface tolerance is similar to the flatness tolerance. However, it uses the geometry of the part to create a tolerance envelope that conforms to the shape of the part, rather than a flat plane. Tolerances for sheet metal parts can be applied to the entire part or specific areas. Local tolerances are indicated on the 2D drawing and are necessary for tighter assemblies in specific locations.Moreover, tolerances (both flatness and profile of a surface) can be free in space, orientation, and position (no datum) or constrained to a specific alignment. This will affect the results, as a fully constrained profile of a surface tolerance will create an envelope that perfectly follows the geometry of the part, without any allowance for movement in space to fit all the points inside the envelope.<h2>Key Points to Inspecting Edges and Corners</h2>Objective: Detecting deformities and irregularities that might have appeared during the cutting and shaping processes.On common sheet metal parts, two types of edges are mostly present: sharp edges and hemmed edges.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817960526-HandySCAN3D_Sheet-Metal-Car-Part-Inspection-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Sharp Edges</h3>Sharp edges are mostly found on sheet metal parts that are laser-cut or stamped with a punch tool or die.<h3>Hemmed Edges</h3>Rather than sharp edges coming from stamping or laser cutting, hemmed edges present a rounded shape found in places prone to injuries, such as the contour of a car door.In the process of stamping and laser cutting sheet metal, certain edges of circles, oblongs, or part sides can become very sharp, which can be dangerous and cause injury or damage if left untreated. Therefore, it is necessary to deburr these edges to break their sharpness and straightness.To ensure that the edges, both hemmed and sharp, are safe and of high quality, manufacturers must accurately inspect their position, angle, and straightness. To achieve this, special algorithms have been developed and contribute to improving sheet metal manufacturing processes.Learn more about VXinspect’s Edge method, designed specifically for sheet metal edges<h2>More Areas to Control on Sheet Metal</h2>Holes, Oblongs, and Cut-Outs: Precision is key for holes, oblongs, and cut-outs in sheet metal parts, as they often need to align with other components. Inspecting these features ensures they are the correct size and properly positioned.Flanges and Tabs: Flanges and tabs are critical for the assembly process. Their dimensions and angles must be precise for proper fitment with other automotive parts.In short, when inspecting these key areas, you can ensure that sheet metal parts are manufactured to the correct dimensions and tolerance. You also confirm that they are the closest to the nominal design, and interference risks are mitigated. With no physical or functional interference, all parts fit together seamlessly and function as intended in the final assembly. As a result, quality, safety, and comfort are optimized.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709817982143-Sheet-metal_Quality-Control_MetraSCAN-3D_Geely-1536x1151.webp" style="width: 100%px;" class="fr-fic fr-dib"><h2 id="isPasted">Which Sheet Metal Parts Are More Challenging to Inspect</h2>Certain parts pose more inspection challenges than others. Here are a few examples.<h3>Roof</h3>The roof of a car plays a vital role in ensuring passenger safety, which is why inspecting it is of utmost importance. However, due to its large size, measuring specific points directly on the assembly line can pose accessibility problems, requiring adapted tools. Therefore, when choosing the right inspection method, it’s not only the part itself that must be considered, but also the condition in which the part is inspected. This is particularly important in an automated quality control (AQC) context or for troubleshooting purposes.<h3>Doors and Fenders</h3>Parts that have structural rigidity once assembled, such as doors, do not need to be physically conformed before inspection. However, other parts, like front and rear fenders, that do not have structural rigidity, must be conformed. Conforming a part can be easy if the appropriate checking fixture is available. (Checking fixtures are typically designed for a specific part.) However, in today’s manufacturing world, production is shifting from Low Mix-High Volume to High Mix-Low Volume. This shift demands more checking fixtures, which in turn adds extra costs to the manufacturing and inspection processes.Holding fixtures are, however, more versatile than checking fixtures. They can be used on multiple parts, which reduces costs and saves storage space. Therefore, holding fixtures to which we add a fast measuring tool can significantly accelerate the conformation process.<h3>Car Body</h3>During the body in white (BIW) stage in which the car body’s frame is joined together, quality control is critical because it involves ensuring the quality of the vehicle’s metal framework before other components like the engine, chassis subassemblies, electronics, and interior trim are integrated into the structure. When inspecting large parts like the car body, pay close attention to the volumetric accuracy of the measuring tool used.Since the measurement deviation increases by a few microns per meter, the cumulative error of scanning a larger part is higher. Such deviations cannot be ignored, and scanning methods have been developed to reduce errors, such as using markers like passive or active targets and photogrammetry.<h2>Next Step: Understand the Technologies for Inspecting Sheet Metal</h2>Sheet metal parts must meet the high standards of quality and safety required by the automotive industry. Inspection is crucial to ensure that the manufactured parts are accurately dimensioned, thereby minimizing waste and reducing the need for rework, ultimately reducing production costs. This efficiency level is critical for any part manufacturer operating in the highly competitive automotive market.However, the manufacturing of sheet metal parts poses certain inspection challenges. To address these challenges, it is essential to select a suitable measuring technology among the different measurement solutions available by analyzing their respective advantages and disadvantages.

Manufacturing sheet metal is far from a simple task. It requires rigorous inspection, primarily due to the high quality and stringent safety standards required in the automotive industry.

Unveiling the Hidden Hurdles of Automotive Part Manufacturers

<div data-id="9908f31" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>A global automotive supplier</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524209040-ti_fluid_systems_IMG_0032.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib">TI Fluid Systems is one of the biggest suppliers for automotive fluid solutions. Source: TI Fluid Systems</div><div data-id="69b735e" data-element_type="widget" data-widget_type="text-editor.default"><a href="https://tifluidsystems.com/" target="_blank">TI Fluid Systems</a> is a manufacturer for automotive fluid technology headquartered in Oxford, England. With more than 100 years of experience and 28’000 employees across 29 countries, the company has established itself as a major supplier to the automotive industry. Primarily, TI Fluid Systems specializes in the development and production of industry-leading fluid carrying systems, as well as fuel tank and delivery systems that are found in two-thirds of all vehicles worldwide.<div data-id="371df47" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Innovation from Poland</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524232497-IMG_8402.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib">Under the lead of Paweł Pułtorak, the Sintratec S2 has been in regular use for over two years at TI Fluid Systems.</div><div data-id="a4a60e8" data-element_type="widget" data-widget_type="text-editor.default">One of TI Fluid Systems 114 branches is located in Bielsko-Biała, Poland, where Paweł Pułtorak has been the head of the design department for the last 18 years. Under his guidance, the team has gradually incorporated additive technologies into their research and development. «3D printing is a very important tool for supporting the work of engineers in the design department», states Pułtorak. With these advanced manufacturing methods, the team is able to reduce production costs and time-to-market.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524259047-1709524259047.png" class="fr-fic fr-dib">The design department uses selective laser sintering to rapidly advance their product development.<div data-id="66f7fc8" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>SLS for precise prototypes</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524288377-cleaningpart_TIFLUID_3-1.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib">SLS parts being depowdered inside the Sintratec Material Handling Station.&nbsp;</div><div data-id="bc27b16" data-element_type="widget" data-widget_type="text-editor.default">«The main use of the 3D prints is to verify the shape and geometry of the designed elements before making the injection mold and going into series production», Pułtorak explains. Due to the high requirements for prototypes in the automotive sector, the company decided to invest in a <a href="https://sintratec.com/sls-3d-printer/amp/sintratec-s2/" target="_blank">Sintratec S2</a> – a selective laser sintering (SLS) system. «Other technologies did not allow us to print as precise components as SLS does», says Pułtorak. With the robust <a href="https://sintratec.com/3d-printing-materials/sintratec-pa12-powder/" target="_blank">Sintratec PA12</a> material in particular, the engineers can cover the majority of the company’s prototyping needs.<div data-id="af667bd" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>A wide range of applications</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524305009-compositesls_web.jpg.webp" style="width: 100%px;" class="fr-fic fr-dib">3D printed with PA12 nylon: Automotive components similar to these are laser sintered by TI Fluid Systems.</div><div data-id="5c13cdf" data-element_type="widget" data-widget_type="text-editor.default">According to Paweł Pułtorak, the Sintratec S2 is used practically every day. «The SLS parts allow us to assess whether there are collisions in our assemblies», explains the department head. «We also use them during our project group meetings and in functional tests.» Apart from the previously mentioned prototypes, the main pieces printed at TI Fluid Systems are housings, construction and tooling elements, jaws and work pieces to assist with assembly, as well as spare parts for the maintenance department.<div data-id="738f8b9" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Accuracy and strength combined</h2></div><div data-id="8731b84" data-element_type="widget" data-widget_type="text-editor.default">«What we like the most about the Sintratec S2 system is the accuracy of 3D printed elements», emphasizes Pułtorak. For the TI Fluid Systems design department, the precision and strength of these components plays a crucial role in their development efforts. After over two years in use, the economic benefits of the Sintratec S2 have become apparent as well. «The machine is definitely a good investment», summarizes Paweł Pułtorak.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1709524343019-1709524343019.png" class="fr-fic fr-dib"></div></div></div></div></div>

At a Polish branch of TI Fluid Systems, functional prototypes and spare parts for the automotive industry are selectively laser sintered. Using a Sintratec S2, Paweł Pułtorak’s team prints precise and complex parts to validate their designs.

Shifting into high gear with SLS

One of the most important challenges in product design is to reconcile form and function. In the automotive industry, for example, the focus is on seamlessly integrating advanced technologies such as touchscreens, digital dashboards and driver assistance systems into the interior without compromising driving comfort or aesthetics. New materials and technologies are broadening the scope of design by enabling innovative and creative solutions that push the boundaries of design.Wire mesh and hybrid mesh from Haver &amp; Boecker have established themselves as versatile materials to fulfil these requirements. The advantages of the design mesh include the wide range of applications, from series production in vehicle construction to object and product design, the interplay of look and feel and the high flexibility of the material.<h2>Wide range of design options</h2>The development of design mesh at Haver &amp; Boecker has a long tradition of innovation. Originally rooted in industrial applications such as sieving and filtration, the company has expanded its portfolio over the years, opening up new areas of application such as design and architecture.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4OTk2NDExMzYxLURlc2lnbmdld2ViZS1Mb2NrZV9VcnNwcnVuZy1ibGF1X3Nsa2FsbGllcnQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Design mesh is characterised by its aesthetic versatility and functional quality, making it possible to create both visually appealing and practical elements (e.g. in the field of filtration).This evolution is reflected in the continuous improvement of the in-house weaving techniques. The design mesh is woven either exclusively from stainless steel wire or from a mixture of metal and colored PET monofilaments. Various manufacturing processes are used to create a wide range of elegant surface textures and striking patterns. &nbsp;It is also highly customizable, both in terms of mesh size and choice of material, giving designers an enormous range of design options.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4OTk2NTMwMDAwLWV6Z2lmLTMtZTM3YmE4OWRiMi5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib">Haver &amp; Boecker design mesh is produced using the latest environmentally friendly processes and is recyclable.The decorative design mesh called HAVER STRUCTURA offers exclusive design possibilities for object and product design, furniture and lamps. It is particularly suitable for decorative elements in car interiors. It adds elegance to the vehicle interior and is translucent and sound permeable. Even surfaces with a closed appearance can be partially or fully backlit. These design fabrics are perfect for covering and cladding objects or individual components in an attractive way.The design mesh collections are available in a variety of patterns, finishes and colours. They can be made entirely of stainless steel or a combination of metal wire, enamelled copper wire and PET monofilament. In addition to black, PET monofilament can be woven in all RAL colours. The range is constantly changing and expanding as a result of new ideas and requests from color and trim designers and developments in weaving technology.<h2>An invitation to creative minds and visionaries</h2>In addition to the focus on design, the company places great importance on sustainability and health compatibility. &nbsp;The versatility, recyclability and reusability of metal wire mesh make this design and filter medium unique for use in future-oriented developments.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA4OTk2NTY3NDgzLURlc2lnbmdld2ViZS1Wb3JoYW5nLWF1Zl9ha2FsbGllcnQuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">Haver &amp; Boecker swatch books help designers choose the right mesh specification - including tactile feedback.With the growing interest in sustainable design and the demand for customised and flexible material solutions, design mesh is likely to play an even greater role in modern design.Haver &amp; Boecker is at the forefront of this development and continues to push the boundaries of what is possible with these materials.<hr>For more information, background and inspiration, please visit us <a href="https://www.haverboecker.com/en/product-solutions/design-mesh/?lso=wevolver-designgewebe-beitrag&utm_campaign=designgewebe&utm_source=wevolver&utm_medium=beitrag&utm_content=022024_en" target="_blank" rel="noopener noreferrer">here</a>.

In the automotive industry, the focus is on seamlessly integrating advanced technologies such as touchscreens, digital dashboards and driver assistance systems into the interior without compromising driving comfort or aesthetics. 

Moldable and stylish: innovative metal meshes inspire designers

At recent 2023 Consumer Electronics Show (CES), Sony and Honda revealed their first electric vehicle prototype, which is equipped with 45 cameras and sensors, as well as Electric Rearview Mirrors. Electronic rearview mirrors have already made an appearance on roads in many countries. A question has been raised: will traditional rearview mirrors eventually become obsolete in smart cars? In this article, we will delve into this inquiry.<h2 dir="ltr">Transform from Light to Electronics</h2>The rearview mirror was invented in 1911 by Elmer Berger, providing drivers with an easier way to view what was behind them while driving. Modifications have been made over the years, including the “day/night” switchable mirror and the “automatic dimming” mirror, making driving safer and more comfortable.Electronic rearview mirrors have emerged in recent years in both commercial and passenger vehicles. However, it should be noted that they have not yet been widely adopted in automobile, let alone replacing traditional rearview mirrors.<h2 dir="ltr">No Wonder It’s Getting Popular</h2>Electronic Rearview Mirror is a new type of “indirect vision device”, also known as the Camera-Monitor System (CMS).The electronic rearview mirror consists of two parts: the “electronic internal rearview mirror” (also known as “streaming media rearview mirror”) is a display screen installed inside the car, and the “electronic external rearview mirror” corresponds to the traditional external rearview mirror on cars. Compared to traditional rearview mirrors, electronic rearview mirrors have three advantages.1. &nbsp; &nbsp; &nbsp;Smaller structure and lower air resistanceIn August 2022, Elon Musk stated on social media that electronic side mirrors on electric cars can reduce energy consumption by about 5%. Since an electronic side mirror is just a camera, its size can be reduced to one-third of a traditional side mirror, or even smaller. From a professional aerodynamics perspective, a smaller structure means a smaller frontal area of the vehicle, which reduces air resistance, reduces wind noise, and to some extent, decreases fuel consumption for combustion engine vehicles and increases the driving range for electric vehicles.2. &nbsp; &nbsp; &nbsp;Less affected by natural factorsWith advancements in camera display and artificial intelligence technology, the solution of “external camera + internal display” can significantly improve the adverse effects of natural conditions, such as rainwater covering side mirrors, fogging, insufficient night lighting, and other problems that plague drivers. In front of electronic side mirrors, these are “child’s play”.3. &nbsp; &nbsp; &nbsp;Smaller blind spotThis is the most intuitive advantage of electronic side mirrors. The curvature, shape, and size of traditional optical reflective mirrors are fixed, resulting in a limited field of view. Electronic side mirrors can use cameras at different angles, providing drivers with a wider field of view. Especially for large commercial vehicles, blind spots are often a fatal area.Electronic rearview mirrors also provide assistance for promotion of car intelligence. Firstly, electronic side mirrors enrich the content of intelligent cockpits. Secondly, it serves as sensors for future autonomous driving systems.<h2 dir="ltr">Not Easy to Get On Board</h2>Although electronic rearview mirrors have many advantages, they also have some limitations. The high cost is a significant drawback, and the stability requirement is high for driving safety. Furthermore, drivers may have difficulty adjusting to the new display screen after using traditional rearview mirrors for over 100 years.But the industry is optimistic that with the decrease in cost and improvement in stability of electronic rearview mirrors, more car companies will embrace electronic rearview mirrors to enhance the differentiation of their models in the process of intelligentization. Though, consumers’ attitudes remain to be seen.<h2 dir="ltr">Order the Parts that Drive Smart Cars Go Faster</h2>“Mirror, mirror on the car, who's the most reliable of them all - traditional or electronic rearview mirrors?” Although there is no definite answer to this question yet, the ongoing process of intelligentization traditional gas-powered vehicles and electric cars is transforming the automotive industry.At RPWORLD, we provide manufacturing services that include CNC machining, injection molding, sheet metal fabrication, and finishing options to help you accelerate your smart drive, faster and more cost-effectively. We have extensive experience in manufacturing a wide range of auto parts for various automotive clients, including:·&nbsp; &nbsp;&nbsp;Exterior parts: head lamp, bumper, radiator, grilles·&nbsp; &nbsp;&nbsp;Interiors parts: EPB, door panels, instrument panels· &nbsp; &nbsp;Electronic parts: battery packs, charging stations, voltage motor

At recent 2023 Consumer Electronics Show (CES), Sony and Honda revealed their first electric vehicle prototype, which is equipped with 45 cameras and sensors, as well as Electric Rearview Mirrors.

Mirror, Mirror on the Car, Who's the Most Reliable of Them All?

As we witness the rise of automated driving, the driver's role is transforming, turning the car into a space for leisure, productivity, and connectivity. The shift from driver to passenger prompts a reimagining of interior concepts.&nbsp;Smart In-Cabin Monitoring Systems (ICMS) are required to enable this transformation, offering intuitive interaction, comfort, and new services while always ensuring and even increasing the safety of all occupants.&nbsp;<h1 dir="ltr">In-Cabin Monitoring Systems</h1>In-Cabin Monitoring Systems monitor and analyse the activities and behaviours of occupants within a vehicle's cabin. Their primary goal is to enhance safety, security, and convenience. Easy said, but a quite challenging and complex task that requires the implementation of multiple use-cases with different requirements.&nbsp;To enable the highest level of safety, the ICMS checks vital signs and detects driver drowsiness as well as readiness to take back from an autonomous driving mode, like a highway pilot. It monitors who is in the car, aiding in seat belt reminders, optimizing airbag deployment, and preventing children from being left behind. Security is increased by proximity and intrusion detection inside and near the car or by spoofing robust face-authentication to enable secure connectivity to private data and personalized services. Finally, to add convenience and to turn the car into a space for leisure, the ICMS has to make real-time body and finger tracking for intuitive interaction, gesture-controlled rear seat entertainment, and a personalized user experience.&nbsp;To fulfill such versatile tasks, the In-Cabin Monitoring System utilizes a combination of sensors, cameras, and artificial intelligence (AI) algorithms. This article focuses on two pivotal technologies that combine to enable cutting-edge ICMSs: radar sensors and Time-of-Flight (ToF) cameras.<h1 dir="ltr">Radar sensors</h1>Radar (Radio Detection and Ranging) sensors emit radio waves and measure the time it takes for the waves to bounce off objects and return. This information is used to determine the object's distance, speed, and even direction. When integrated into the cabin environment, radar sensors enable a range of unobstructed in-cabin sensing (1). The ability to measure through most materials and the sensors’ small package size means they are able to be designed seamlessly into the car's design. Furthermore, the low power consumption even allows for operating a radar system in a parked car.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2NzkyNjE4MjgzLUlNQUdFUy0wMSAoMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">The radar working principle.<h1 dir="ltr" id="isPasted">Time of Flight (ToF) Cameras</h1>Time-of-Flight (ToF) cameras transmit modulated infrared light onto the scene of interest. The ToF imager captures the reflected light and measures amplitude and phase difference per pixel. The result is a 3D image of the entire scene consisting of the exact distance per pixel plus a gray-scale image. It operates in all lighting conditions: in darkness, strong sunlight or fast-changing lighting conditions. ToF provides the most robust and feature-rich data for vision-based algorithms and the generation of detailed 3D body models of passengers and objects.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2NzkyNjUzNzMyLUlNQUdFUy0wMiAoMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">Time-of-Flight working principle.<h1 dir="ltr" id="isPasted">In-Cabin Sensing Use Cases</h1>Radar and Time-of-Flight are, by principle, two completely different technologies. As described, radar sensors utilize radio waves, having the benefit of overcoming occlusions of the car seats, having ultra-low power consumption, and the ability to detect tiny movements like the chest movements of a breathing baby. On the other hand, you do not get any image data of your surroundings in order to detect facial expressions or gaze direction or to do detailed object classification. Meanwhile, ToF cameras provide such details together with the exact distance information while being limited to the field-of-view of the camera lens, the pixel resolution, and occlusions. Both technologies have unique merits and limitations, making them suitable for distinct applications. When having a closer look, they are complementary, and the combination of radar and ToF results in a more robust ICMS that gathers data from two distinct sources to cover all major in-cabin use cases.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2NzkxOTYyMzA2LTE3MDY3OTE5NjIzMDYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">As discussed above, radar sensors and ToF can be combined to create ICMSs that have a broad range of features, utilizing the strengths of each technology resulting in more effective and meticulous monitoring. Below we look at some of the features of a cutting edge ICMS and highlight how each case scenario is delivered using radar and/or ToF sensors.<h3 dir="ltr">Child Presence Detection (CPD)</h3>A particularly advantageous feature of an ICMS is the ability to monitor the occupancy of the car’s interior. Occupancy detection is especially useful to sense the presence of unattended children or pets in a vehicle. According to the US Department of Transportation, an average of 38 children under the age of 15 die each year from heat stroke after being left in a vehicle (2). To address the issue, the US Congress issued the Hot Car Act 2021 (3) and the Euro NCAP announced additional award points to vehicle manufacturers who implement the child presence detection (CPD) feature (4).&nbsp;A radar sensor is able to scan the area within the vehicle, including seats and footwell areas, and prompt the ICMS to send out a warning if any vital signs are detected while the car is parked and the temperature has reached a certain level. The operation of radars is unobstructed by seating and other non-metal materials, making them able to detect children and pets in back seats, infants placed in rear-facing seats, and even children covered by objects such as blankets.&nbsp;<h3 dir="ltr">Seat Occupancy Detection and Smart Airbags</h3>Seat Occupancy Detection (SOD) localizes the number of vehicle occupants and their specific&nbsp;<iframe id="641421a7785b8e00080e09d6" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/infineon-bgt60ltr11aip-autonomous-radar-sensor?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> locations to optimize seatbelt reminder (SBR) systems and airbag deployment systems. The radar senses when a seat is unoccupied, and then the ICMS communicates to the vehicle’s airbag control module, preventing the airbag from deploying in case of an accident.&nbsp;While radar sensors detect occupancy, ToF cameras allow an ICMS to create 3D body models of the driver and passengers. This information can be used to make accurate passenger size and weight estimates and provides the exact positioning of occupants towards the airbag, which can effectively aid in optimized airbag deployment. In particular during autonomous driving modes, when drivers will be allowed to change their seat position, the ICMS can provide the necessary data to adapt airbags and restraints for maximum safety.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2NzkzMTY4NTk5LUZyb250IHZpZXcgLSBUb0YgZGF0YSBvdmVybGF5IG9mIGRlb3B0aCBhbmQgYW1wbGl0dWRlLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib">Infineon’s Time of Flight (ToF) sensors showing a depth map of in-cabin environment.Another potential application of SOD lies in seatbelt alerts. In this case, radar can be used to check whether a seat is occupied and coordinate with the seat belt detection systems of the car to check if the passenger is buckled in or not. With the complementary ToF data, the ICMS could even see if the seatbelts are fastened correctly.As described, having both data from radar and ToF sensors available increases the robustness of the use cases, and the kind of redundant data also supports meeting functional safety requirements for airbag applications.<h3 dir="ltr">Intrusion Alert</h3>Radar sensing allows an ICMS to detect when an intruder tries to gain access to a vehicle. This is done by programming the ICMS to detect when an object such as a hand or weapon is inserted into the car through a window, sunroof, or the trunk, and in turn sound an audible alarm or notify the driver on a smart device. This allows the monitoring system to protect the car from theft and secure the interior contents using intrusion alert systems.<h3 dir="ltr">Proximity Alert</h3>The internal environment of a vehicle is not the only area that can be monitored using radar sensing. Radars can also be used for constantly monitoring the close proximity of a vehicle and detect if another vehicle is too close or if a person is attempting to damage or break in. Based on this information, an alarm system can be triggered to flash the headlights or honk the horn to ward off potential intruders. Additionally, a notification can also be sent to the driver if they are not near the vehicle.&nbsp;Having the right radar system and algorithms, it is possible to enable all above mentioned use cases of CPD, SOD, SBR, and intrusion- and proximity alert with just one radar sensor per car.<h3 dir="ltr">Secure Face Authentication and Driver Monitoring</h3>A unique feature of in-cabin ToF cameras is 3D face authentication – securing your vehicle using facial recognition. Incorporating depth-sensing technology, as seen in smartphones and payment terminals, delivers the highest quality of anti-spoofing security. This functionality enables the real connected car, where a driver has seamless access to private data or personalized services like music streaming or any payment functionality – whenever there is the need to authenticate.&nbsp;Once a 3D ToF-based driver monitoring camera is installed for 3D face-ID, the same camera can also be used for the basic driver monitoring system (DMS) functionality to ensure drivers are alert to the road: to monitor the driver’s head movement, eye closure and gaze direction and to flag any distraction or signs of drowsiness.Furthermore, knowing the exact eye position by the 3D ToF data helps to optimize projection features like the optimal view onto a head-up display (HUD).<h3 dir="ltr">Personalized Comfort</h3>Once the vehicle has authenticated who the driver is, the system is able to adjust the vehicle's interior to that driver’s personal preferences. A ToF camera recognizes the driver, and the ICMS can then adjust the seat position, climate control, and entertainment settings to create a personalized and comfortable cabin space.&nbsp;<h3 dir="ltr">Enhanced Gesture Control</h3>While gesture control has been around for a while, it has been limited to a very narrow zone near the driver. A ToF sensor with higher resolution enables a wider field of view with enough spatial resolution to properly detect and track fingers enabling passengers to adjust entertainment settings etc, without touching an interface. It even allows interaction with smart surfaces and projections like HUDs and holographic visualizations.In particular for rear seat entertainment systems, gesture interaction can be very convenient and provides a kind of fun factor and the best entertainment content, like the possibility of gesture-controlled video games. Besides hand- and finger gestures, also body gestures can be used for a most convenient user experience. A ToF camera, for example detects if a passenger is reaching out to a certain area in the car and the interior light is illuminating just this area.It should be mentioned that depending on the use case the right camera specification and placement have to be considered.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2NzkyNzE0ODg5LUlNQUdFUy0wMyAoMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib">Combination of radar and ToF sensors enable the maximal amount of in-cabin monitoring use-cases.<h1 dir="ltr" id="isPasted">Infineon’s In-Cabin Solutions</h1>Infineon Technologies has paved the way for a transformative shift in automotive technology by introducing innovative products for in-cabin monitoring. Infineon’s automotive radar sensors and Time-of-Flight solutions are shaping the realm of in-cabin monitoring and detection systems, redefining safety, security, comfort, and user experience within vehicles.&nbsp;Infineon's XENSIV™ 60GHz radar transceiver, a powerful yet cost-effective innovation, sets the stage for advanced safety features (5). Operating in the 58 to 62 GHz frequency range, the BGT60ATR24 radar sensor family boasts two transmit, and four receive channels and a low-noise phase-locked loop. The radar is designed with an integrated anti-aliasing loop filter, finite state machine, and RX baseband with ADC ensuring high-performance data precision, which is crucial for safety features like occupancy detection. The BGT60ATR24AIP features Infineon’s antenna in package technology, enabling a very small footprint while reducing efforts at customer side to design antennas. The radar sensor is able to address numerous passive safety applications like left-behind child and pet detection, driver vital monitoring, and occupancy sensing due to its ability to sense micro motions.To complement the benefits of the radar sensor, Infineon offers its automotive-grade REAL3™ ToF sensors IRS2877A(S) (6). IRS2877A offers a VGA system resolution of 640 x 480 pixels arranged in a way that minimizes crosstalk while maximizing performance and achieving an image circle of only 4mm for the smallest possible lens- and as such, module sizes. Additionally, each pixel is equipped with a patented Suppression of Background Illumination (SBI) circuitry enabling the ToF cameras to operate in all lighting conditions and exhibit sunlight robustness.&nbsp;All of this is packaged in a highly minimized plastic package with a footprint of only 9x9 mm, making it fit seamlessly into the interior of a vehicle. This combination of compact size and impressive resolution opens the door to innovative automotive applications, including secure face authentication, driver monitoring and wide-field-of-view in-cabin sensing cameras. IRS2877AS is the ISO 26262 (ASIL-B) compliant variant to address functional safety requirements like smart airbags, the world’s first of its kind.The flexibility of both sensors allows for discrete integration within the cabin, ensuring their effectiveness without compromising aesthetics. Customer needs, operating conditions, and budgetary limitations determine the number and placement of sensors, optimizing coverage and enabling desired functionalities. Combining data from both sensors can achieve a robust and comprehensive In-Cabin Monitoring System.<h2 dir="ltr">Conclusion</h2>The use of radar and ToF sensors in In-Cabin Monitoring Systems represents a significant leap forward in automotive safety and user experience. Integrating features like occupant detection and fine-grained monitoring, ICMSs powered by these sensors have the potential to transform driving into an intelligent, safer, and more personalized experience. As sensing technologies continue to evolve, we can anticipate exciting improvements in the precision, range, and overall capabilities of ToF and radar sensors, paving the way for even more sophisticated applications as we head towards full autonomy.&nbsp;<h2 dir="ltr">References</h2>1. &nbsp; &nbsp;Soldatos J. Why Radar Sensors are Powerful Enablers for Intelligent IoT Applications [Internet]. [cited 2023 Sep 30]. Available from: https://www.wevolver.com/article/why-radar-sensors-are-powerful-enablers-for-intelligent-iot-applications2. &nbsp; &nbsp;Automotive News Europe [Internet]. 2022 [cited 2023 Oct 1]. How to make vehicles safer against hot car deaths. Available from: https://europe.autonews.com/guest-columnist/how-make-vehicles-safer-against-hot-car-deaths3. &nbsp; &nbsp;Hot Car Act 2021 [Internet]. 117th Congress (2021-2022) [cited 2023 Dec 15] https://www.congress.gov/bill/117th-congress/house-bill/31644. &nbsp; &nbsp;Euro NCAP. Euro NCAP roadmap 2025 [Internet]. Leuven; 2017 Sep p. 19. Available from: https://cdn.euroncap.com/media/30700/euroncap-roadmap-2025-v4.pdf5. &nbsp; &nbsp;Infineon Technologies. 60GHz radar sensors for automotive | Interior sensing - Infineon Technologies [Internet]. [cited 2023 Oct 2]. Available from: https://www.infineon.com/cms/en/product/sensor/radar-sensors/radar-sensors-for-automotive/60ghz-radar/6. &nbsp; &nbsp;Infineon Technologies. ToF 3D image sensors for automotive - Infineon Technologies [Internet]. [cited 2023 Oct 2]. Available from: https://www.infineon.com/cms/en/product/sensor/tof-3d-image-sensors/tof-3d-image-sensors-for-automotive/

As cars shift to automated driving, In-Cabin Monitoring Systems (ICMS) are vital for passenger safety and comfort. Incorporating Time-of-Flight cameras and radar sensors enables ICMS to detect occupants and their behaviors promising a safe and personalized automotive experience.

Steering Towards Safer Rides: The Role of Radar and ToF Sensors in In-Cabin Monitoring Systems (ICMS)

The SAE Racing Team of the Munich University of Applied Sciences designs and builds its own racing car from scratch every year as part of the Formula Student racing series and participates in events all over Europe. The high demands on individually manufactured components and the material properties make 3D printing indispensable for the development of motorsport. We were able to accompany Niklas Rösler and his team at the largest Formula Student event at the Hockenheimring.<iframe width="640" height="360" src="https://www.youtube.com/embed/mJ_uzANMilk?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true">&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</iframe><div data-id="c66a2bb" data-element_type="widget" data-widget_type="heading.default" id="isPasted"><h2>Picking up speed in your studies</h2></div><div data-id="a063078" data-element_type="widget" data-widget_type="text-editor.default">The interdisciplinary team of <a href="https://munichmotorsport.de/" target="_blank">munichmotorsport</a> is made up of about &nbsp;40 students from different faculties and disciplines of the <a href="https://www.hm.edu/en/index.en.html" target="_blank">Munich University of Applied Sciences</a>. From automotive, electrical and mechanical engineering to business administration, design, and marketing, the team bundles its competencies to fulfill all disciplines of the <a href="https://www.formulastudent.de/fsg/" target="_blank">Formula Student</a> racing series. In one of the biggest engineering competitions of the world, approximately 100 teams not only compete against each other on the race track but also have to prove their skills in static disciplines such as business planning and cost calculation.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2Njg1MDg3NTY3LTE3MDY2ODUwODc1NjcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 768px;" class="fr-fic fr-dib">Every year, around 100 teams take part in the largest Forumula Student Event at the Hockenheimring in Germany.<h2>Unique rapid prototypes thanks to SLS 3D printing</h2><div data-id="fbef267" data-element_type="widget" data-widget_type="text-editor.default">Almost all the parts needed for the interior of the fully electric race car are one-offs that have to be manufactured over a short period of time. '3D printing offers the best prototyping platform for us to manufacture, our housings and brackets built into the car', explains Niklas Rösler. The engineering student was in charge of the car’s high-voltage system this year.&nbsp;Due to their complex geometry, many of the required components are usually impossible or very cost-intensive to realize using conventional manufacturing technologies. 'SLS 3D printing is the most suitable prototyping technology for us. We can use it in almost every situation around the car', Rösler notes.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2Njg1MTUxNTI1LUZTVF9NdW5pY2gtRmVhdHVyZUltYWdlLndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 302px;" class="fr-fic fr-dib">The Munich motorsport team busy in the pits preparing the car for the dynamic disciplines.“SLS 3D printing is the most suitable prototyping technology for our racing team. We can use it in almost every situation around the car.” - Niklas Rösler, Prototyping Technician, munichmotorsport. <h2>Stable and safe with PA12</h2><div data-id="2c67180" data-element_type="widget" data-widget_type="text-editor.default">SLS 3D printing meets the requirement for almost all applications in the car. &nbsp;One of Rösler’s tasks was to make sure that the battery cells are well stored and that the cooling of the system is also guaranteed. To that end he developed housings which were subsequently 3D printed with <a href="https://sintratec.com/3d-printing-materials/sintratec-pa12-powder/" target="_blank">PA12</a> and on the <a href="https://sintratec.com/sls-3d-printer/amp/sintratec-s3/" target="_blank">Sintratec S3</a>. This component stabilizes the individual battery cells in the vehicle’s rear and ensures a firm hold during rapid load changes and three-dimensional force application.&nbsp;For use in electric vehicles, dielectric strength plays a very important and safety-relevant role. For cooling the entire system, spacers, also made of PA12, are used to regulate the airflow. 'The PA12 material from Sintratec covers most areas of application in the race car. It offers the best mechanical properties for our purposes and high dielectric strength', Rösler says.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2Njg1MTg4NzA4LUN1c3RvbWVyU3RvcnlQaWN0dXJlX0ZTR19NdW5pY2hfSW5zZXJ0VGhlQmF0dGVyeV93ZWIuanBnLndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 302px;" class="fr-fic fr-dib">3D printed components for the high-voltage system made with PA12.<h2>Constant potential for improvement</h2><div data-id="fc3658e" data-element_type="widget" data-widget_type="text-editor.default">The race weekend of the Formula Student main event was visibly exhausting for Niklas Rösler and his team, but successful. After initial technical problems, the team achieved a good run in the autocross and also scored plenty of points in the static disciplines. In the overall standings, the team secured 20th place out of 71 participating teams in the electric class.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzA2Njg1MjE5NTc5LTE3MDY2ODUyMTk1NzkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib">'We are very proud of the performance and the design of the car, and above all, of what we have achieved and accomplished as a team in the past year,' Rösler sums up. He and his team are sure to rely on 3D printing again next year</div></div></div></div>

The high demands on individually manufactured components and the material properties make 3D printing indispensable for the development of motorsport.

SLS 3D printing on the fast track

Mock-ups are scaled or full-size models of a design that are used for various purposes, such as aesthetic design evaluation, fit-testing, product testing, demonstration, teaching, and promotion. In the Automotive industry, these physical models of car designs range from simple sketches to full-scale prototypes. Made of various materials, such as clay, foam, plastic, or metal, they are essential for validating the functionality, aesthetics, and performance of new car concepts before they go into production. They are important for custom-made cars and vehicle development for several reasons.<h3>The impact of 3D printing on Mock-ups and Full-scale Prototypes in the Automotive Industry</h3>Large format additive manufacturing (LFAM) is an innovative technology that enables the creation of large parts or structures by depositing layers of material, such as plastic, metal, or composite, using a print head controlled by slicing and automation software.As traditional methods of making mock-ups can be costly, time-consuming, and wasteful, LFAM systems are increasingly adopted in this specific application. Through the use of large-scale 3D printers, the production and supply chain of automotive mock-ups can benefit from several advantages, such as:<ul style="list-style-type: circle;"><li>Faster manufacturing;</li><li>Reduced material waste and cost;</li><li>Improved quality and accuracy;</li><li>Enhanced design freedom and innovation.</li></ul><h3>Read more on why 3D printed mock-ups are important for the Automotive industry and how Caracol and Titans of CNC collaborated on the front grille 3D printed mock-up and end-use custom part for a 1968 Chevrolet C10 custom build by Gas Monkey Garage, Dallas (Texas) <a href="https://www.caracol-am.com/resources/case-studies/how-large-3d-printed-mock-ups-can-accelerate-the-automotive-industry" target="_blank" rel="noopener noreferrer">at this link</a>.</h3>

Working on custom car projects Caracol has seen how large 3D printed mock-ups can help accelerate product development in the automotive industry, from concept design to fitting and production.

How large 3D printed mock-ups can accelerate the automotive industry

What started out in 1928 as a blacksmith and carriage smithy is now, 94 years later, a modern, customer-focused vehicle manufacturing company in the heart of Switzerland. These days, <a href="https://sutter-fahrzeugbau.ch/" target="_blank">Sutter AG Lungern Fahrzeugbau</a> specializes in the development and manufacture of 3-side tippers of up to 40t, loading bridges for all trucks and vans, box bodies, tipping bodies, quick-change systems, special vehicles, maintenance and repairs of bodies and trailers.Before purchasing the Creaform 3D scanner, engineers at Sutter spent about 5% of their working time manually measuring certain components with complex geometries to fit them to vehicles. These are mainly aluminum covers, underride guards, crane mounting elements, and other vehicle mounted components that are tailored to the requirements of the vehicle or the customer’s wishes. Before, these parts used to be manufactured without the possibility of double-checking them prior to the time of final assembly, as it was not possible to check the geometries on the vehicle itself. Apart from the extended amount of time it took to develop the components, the effort and expense required to have them modified and adapted by qualified metal workers for their final place of use was enormous.<h2 id="isPasted">Requirements for a new&nbsp;measuring system and implementation</h2>Sutter often has to deal with large scanning areas, such as truck chassis zones, where the distance between the individual components is important, yet the measurement accuracy must remain high. The crucial requirement in purchasing the measurement system was therefore accuracy.One of the key factors in choosing <a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">Creaform Go!SCAN SPARK</a> was the ability to purchase not just a product, but a complete service. This included the purchase of consumables for the use of the scanner, a laptop, support for the work on site, after-sales service in case of maintenance, repairs, and questions.The implementation of Creaform’s 3D measurement solutions was very intuitive, as it did not require a new process to be defined, only for an existing one to be replaced. In practice, the manual measurement process was simply replaced by 3D scanning. This not only provided the design department with more measurement data, but also allowed them to check the actual dimensions and geometries of vehicle components during development (a double-check).Since Sutter AG is a small company, the entire process from 3D scanning to ordering raw materials for manufacturing the components, such as sheet metal, is handled by one of the engineers in the engineering department. A single two-day training session by a Creaform technician made it possible for Sutter to be fully operational and independent right from the start.<h2>Truck add-on parts: Teamwork between Creaform Go!SCAN SPARK, engineering department and workshop<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1703242760665-DJI_0032-1536x1152.webp" style="width: 300px;" class="fr-fic fr-dib"> </h2>Sutter AG handles a multitude of diverse projects. As an example, we would like to show how the design, manufacture, and assembly of a customized tool box on an existing truck chassis for the transport of construction machinery was created in cooperation between the workshop and the engineering department.Due to current delivery bottlenecks at the vehicle manufacturer, the “construction machine taxi” project was created under tight time constraints. This meant the engineering department had to do a lot of advance preparation using CAD designs. When the vehicle arrived, an advanced design status was achieved very quickly and the workshop itself built some additional attachment holders for tool boxes.Another application Sutter has found for the technology is to ensure traceability in the archive in accordance with the ISO9001 standard. It was therefore decided to scan the additional mounting bracket with the <a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">Creaform Go!SCAN SPARK</a>.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1703242783515-Sutter_Bild1.webp" style="width: 300px;" class="fr-fic fr-dib">Area with additional mounting bracket for toolboxes to be scannedAlthough the additional mounting bracket has a wide variety of surface finishes, colors, and geometries, it took very little time to scan and the amount of material required (targets and matting spray) was very low.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1703242805422-Sutter_Bild2.webp" style="width: 300px;" class="fr-fic fr-dib">3D scan of the truck chassis with additional elements mounted by Sutter in the VXmodel softwareWith the help of the <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank" id="isPasted">VXmodel</a> export function, everything could be imported directly into Solidworks and traced very quickly. This was mostly done using the measurement function, the creation of geometry (such as profiles, planes, and cylinders) in VXmodel, and then with the direct transfer of the geometries into Solidworks.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1703242824162-Reverse-engineering-1536x934.webp" style="width: 300px;" class="fr-fic fr-dib">Reverse engineering in SolidworksWhere possible, purchased parts were replaced with 3D data from parts suppliers. However, this does not happen as a rule, since missing 3D models are often replaced by mesh bodies from 3D scans. This method of working also increases the quality and completeness of the company’s own database of purchased parts.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1703242846791-Sutter_Bild3.webp" style="width: 300px;" class="fr-fic fr-dib">CAD view of the scanned areas with traced toolbox holders and purchased part (hydraulic tank)<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1703242859867-Sutter_Bild4.webp" style="width: 300px;" class="fr-fic fr-dib">CAD view with bridge (main design, manufactured by the engineering department), hydraulic tank (from 3D data from parts supplier), and toolboxes (holders built by the workshop and redesigned through reverse engineering<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1703242876399-Sutter_Bild5.webp" style="width: 300px;" class="fr-fic fr-dib">Finished body<h2 id="isPasted">How the Go!SCAN SPARK with VXmodel has improved processes and practices at Sutter AG</h2>Apart from the main requirement of accuracy already mentioned before, there have been several improvements at a practical level:<ul><li>The space analysis in the planning of bodies, but also of additional units and attachments, has been greatly simplified.</li><li>The accuracy of measurements and the production of raw parts have been increased.</li><li>Quality management has been improved and it is now possible to track completed and similar projects.</li><li>The waste rate of raw parts has been reduced or brought to zero.</li><li>The assembly and adaptation time by the workshop has been reduced, which avoids the need for highly trained employees (the objective is a plug &amp; play strategy).</li></ul>In terms of software, the <a href="https://www.creaform3d.com/en/metrology-solutions/3d-applications-software-platforms/vxmodel-scan-cad-software-module" target="_blank">VXmodel software module</a> used by Sutter enables the data to be scanned, processed, and aligned with the correct coordinate system quickly and easily, and finally exported directly to the Solidworks CAD drawing program. The biggest advantage is definitely the possibility to export the raw data directly into the Solidworks format. There, the data can be used for CAD comparisons or as an aid for designing further parts.All these factors have led to considerable improvements in internal processes and shared practices in the execution of projects.<h2>Future areas of application</h2>Sutter’s central idea is to gradually increase the use of the <a href="https://www.creaform3d.com/en/handheld-portable-3d-scanner-goscan-3d" target="_blank">Creaform 3D scanner</a> in order to spread the technical and practical benefits across all industries and product types.Burim Shala, Technical Manager at Sutter comments: “Another step we would like to take as a company is to scan purchased standard components for which there are no 3D models, so that we can plan and design our products with even more detail and precision. We would like to use the 3D scanner mainly for preliminary clarifications so that we can design earlier in the manufacturing process. In a nutshell, I would say that Creaform measurement solutions help us keep the focus on the ‘golden triangle’.”<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1703242902521-Golden-Triangle.webp" style="width: 300px;" class="fr-fic fr-dib">Blue triangle. At the top corner is says “Quality,” at the bottom left corner “Time,” at the bottom right corner “Cost.”

The use of the Go!SCAN SPARK and VXmodel leads to significant improvements in the internal processes when carrying out projects at the Swiss company Sutter AG.

Vehicle manufacturing company uses 3D scanners to increase design quality and optimize engineering times

The automotive landscape is undergoing a significant change, driven by a surge in software-defined vehicles (SDVs) and a growing emphasis on cybersecurity, reliability, and quality. This shift marks a departure from traditional vehicular designs, where mechanical prowess reigned supreme, to a new era where software capabilities are equally, if not more, crucial.&nbsp;This evolution signifies a profound change: vehicles are no longer just modes of transportation but are becoming sophisticated, interconnected mobile devices. In this dynamic environment, innovation is not just about horsepower and torque; it’s about bytes and software codes, opening up new realms of possibilities in automotive design, safety, and functionality.Amidst these advancements, a substantial concern has emerged within the industry. A recent study found that 84% of the professionals responsible for contributing to the security of automotive components, have concerns that cybersecurity practices are not keeping pace with the rapidly evolving technologies in the automotive sector.[1]&nbsp;This underscores a critical need for more advanced and adaptive cybersecurity measures to match the pace of innovation in vehicle technology.In this article, we will delve into the intricate convergence of software and hardware reshaping the automotive world. From the rise of SDVs, to the paramount importance of cybersecurity in an increasingly connected ecosystem, we explore the multifaceted challenges and opportunities in this sector. As we approach the end, we will take a look at Synopsys' contributions, underscoring how their expertise is steering the automotive industry towards a more secure and advanced future.<h1 dir="ltr">The Rise of Software-Defined Vehicles</h1>Software-defined vehicles (SDVs) represent a new paradigm in the automotive industry, where the core functionalities and features of a vehicle are increasingly controlled and enhanced by software. Unlike traditional cars, where mechanical systems were the primary focus, SDVs rely heavily on software for everything from engine management to advanced driver-assistance systems (ADAS). This shift means that software now plays a critical role in defining a vehicle's capabilities, user experience, and performance.<h2 dir="ltr">Benefits of SDVs</h2>The transition to SDVs brings several key benefits:<ul><li dir="ltr">Enhanced Safety through ADAS:&nbsp;SDVs leverage sophisticated software to power ADAS features like adaptive cruise control, lane departure warnings, and collision avoidance systems. These systems use a combination of sensors, cameras, and algorithms to interpret traffic conditions, providing real-time assistance and reducing the likelihood of accidents.</li><li dir="ltr">Customizable User Experience:&nbsp;The software-centric nature of SDVs allows for a high degree of customization. Owners can personalize driving modes, infotainment systems, and interior environments. Software updates can also introduce new features or improve existing ones, ensuring the vehicle stays current with the latest technologies.</li><li dir="ltr">Improved Vehicle Efficiency and Performance:&nbsp;Advanced software algorithms in SDVs optimize engine performance, battery management (in electric vehicles), and energy consumption. This leads to better fuel efficiency in conventional vehicles and extended range in electric models. Software can also enhance vehicle dynamics, such as steering and braking, for a more responsive driving experience.</li><li dir="ltr">Seamless Integration with IoT and Smart Cities:&nbsp;SDVs are designed to seamlessly integrate with the Internet of Things (IoT) and smart city infrastructures. This enables features like vehicle-to-infrastructure (V2I) communication, where vehicles can receive information about traffic conditions, weather, and road closures, leading to more efficient route planning and reduced congestion.</li><li dir="ltr">Predictive Maintenance and Diagnostics:&nbsp;SDVs can constantly monitor vehicle health and predict maintenance needs before they become serious issues. By analyzing data from various sensors, the vehicle's software can alert the owner about wear and tear on parts, potentially preventing breakdowns and reducing long-term maintenance costs.</li></ul><h2 dir="ltr">Challenges with SDVs</h2>Despite these benefits, the rise of SDVs also introduces several challenges:<ul><li dir="ltr">Cybersecurity Risks:&nbsp;As vehicles become more connected, they are more vulnerable to cyber-attacks, making robust cybersecurity measures essential.</li><li dir="ltr">Complexity in Design and Integration:&nbsp;Integrating complex software systems with traditional mechanical components requires a new level of design sophistication and poses significant engineering challenges.</li><li dir="ltr">Need for Reliable Software:&nbsp;The dependence on software means that any bugs or malfunctions can have serious implications for vehicle safety and functionality. This necessitates a high standard for software development and testing in the automotive industry.</li></ul><h1 dir="ltr">Cybersecurity in the Automotive Sector</h1>In the era of connected and autonomous vehicles, cybersecurity has become a cornerstone of automotive safety. As cars evolve into sophisticated networks on wheels, they are increasingly exposed to cyber threats that can compromise not only the privacy and data of users but also their physical safety. The integration of features like Wi-Fi, Bluetooth, and cellular connectivity opens up multiple channels for potential attacks. Additionally, as vehicles become more autonomous, the reliance on software systems intensifies, making robust cybersecurity measures crucial to ensure the safe operation of these vehicles.<h2 dir="ltr">Gaps in Current Cybersecurity Practices</h2>A study by Synopsys and SAE International sheds light on the current state of cybersecurity practices in the automotive industry.[1]&nbsp;It highlights a growing awareness of cybersecurity importance but also reveals gaps in implementation. Some key findings include:<ul><li dir="ltr">Limited Integration in the Development Process:&nbsp;Cybersecurity is often considered late in the development process, rather than being integrated from the beginning. There is an increasing need for holistic cybersecurity strategies that encompass the entire vehicle lifecycle, from design to decommissioning.</li><li dir="ltr">Third-Party Risks:&nbsp;Modern vehicles often rely on software and components from multiple suppliers, which can introduce security risks if not properly vetted and integrated.</li><li dir="ltr">Inadequate Training and Awareness:&nbsp;There is often a lack of adequate training and awareness regarding cybersecurity among automotive staff. This gap in knowledge and skills can lead to vulnerabilities in vehicle software and systems.</li><li dir="ltr">Insufficient Testing and Validation:&nbsp;Many organizations in the automotive sector do not have robust processes for testing and validating cybersecurity measures. This can result in overlooked vulnerabilities and weak spots in vehicle cybersecurity.</li><li dir="ltr">Reliance on Legacy Systems:&nbsp;Some automotive manufacturers still rely on legacy systems that were not designed with modern cybersecurity threats in mind. This reliance can create significant security risks, especially as vehicles become more connected and integrated with external networks.</li><li dir="ltr">Fragmented Regulatory Landscape:&nbsp;The regulatory landscape for automotive cybersecurity is often fragmented and inconsistent across different regions and countries. This lack of uniform standards can make it challenging for manufacturers to implement comprehensive and globally applicable cybersecurity strategies.</li><li dir="ltr">Connected Vehicle Security:&nbsp;As vehicles become more connected, ensuring secure communication both within the vehicle and with external networks becomes critical to prevent unauthorized access and data breaches.</li></ul><h1 dir="ltr">Advancements in Automotive Silicon and Electronics</h1>The evolution of automotive electronics marks a significant shift from basic electrical components to complex electronic systems. In the early days, vehicles primarily used simple circuits for lighting and ignition. Today, they are equipped with advanced electronic control units (ECUs) that manage everything from engine performance and transmission to infotainment and climate control. This evolution reflects the growing role of electronics in enhancing vehicle functionality, efficiency, and safety. Modern vehicles are now akin to moving computers, with sophisticated networks that integrate multiple sensors, actuators, and control systems.<h2 dir="ltr">Role of Silicon in Modern Vehicles</h2>Silicon components, particularly system-on-chips (SoCs), have become the backbone of modern vehicle electronics. SoCs integrate multiple functionalities onto a single chip, leading to more efficient, compact, and powerful electronic systems. These components are essential for processing the vast amounts of data generated by ADAS, managing electric vehicle (EV) power electronics, and powering infotainment systems. The importance of silicon in vehicles extends beyond performance to include aspects like energy efficiency, which is critical for EVs, and the ability to support ongoing software updates and enhancements.<h2 dir="ltr">Challenges with E/E Architectures</h2>The shift to more complex electronic/electrical (E/E) architectures in vehicles brings several challenges:<ul><li dir="ltr">Integration Complexity:&nbsp;As the number of electronic components and systems in a vehicle increases, so does the complexity of integrating them. Ensuring seamless communication and functionality across different systems is a significant engineering challenge.</li><li dir="ltr">Reliability and Safety:&nbsp;With increased reliance on electronic systems, ensuring their reliability and safety becomes paramount. Any failure in these systems can have dire consequences for vehicle operation and passenger safety.</li><li dir="ltr">Efficiency and Size Constraints:&nbsp;Designing E/E architectures that are not only robust and reliable but also efficient and compact is another challenge. This is especially important in EVs, where space and power efficiency are crucial considerations.</li></ul><h1 dir="ltr">Synopsys: Steering Automotive Innovation</h1><a href="https://www.synopsys.com/" target="_blank">Synopsys</a> has emerged as a key player in driving automotive innovation, particularly in the realm of software and silicon solutions. With a focus on developing tools and technologies that cater to the specific needs of the automotive industry, Synopsys is at the forefront of enabling the next generation of software-defined vehicles. Their expertise in electronic design automation, semiconductor IP, and software security and quality is instrumental in addressing the complex challenges of modern automotive systems.<h2 dir="ltr">Synopsys' Solutions for Automotive Innovation</h2><ul><li dir="ltr">Optimizing SoC &amp; E/E Architectures:&nbsp;Synopsys provides comprehensive solutions and services for designing and verifying SoCs and E/E architectures. Their tools help in creating differentiated systems that are not only safe and secure but also efficient and scalable, meeting the stringent demands of the automotive industry.</li><li dir="ltr">Software Validation for SDVs:&nbsp;Recognizing the critical role of software in SDVs, Synopsys offers advanced solutions for software development and validation. Their technologies streamline the development process, reducing time-to-market while ensuring high standards of quality and reliability.</li><li dir="ltr">Enhancing Vehicle Safety &amp; Security:&nbsp;Synopsys' commitment to safety and security is evident in their suite of tools and services. They provide solutions that help automotive companies meet rigorous safety standards and security requirements, ensuring that both software and silicon components are robust against potential threats.</li></ul>Visit&nbsp;<a href="https://www.synopsys.com/automotive" target="_blank">Synopsys Automotive Solutions</a> page to learn more.

Advanced software, sophisticated silicon designs, and strong cybersecurity are key technologies transforming today's vehicles, leading the shift towards more intelligent, secure, and efficient automotive systems.

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Example output of DeepScenario’s AI software that detects and tracks all moving objects in a scene in a fully automated way. (DeepScenario) 

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Based on the latest International Energy Agency (IEA) projections (featured in the newest edition of the <a href="https://www.iea.org/reports/global-ev-outlook-2023" target="_blank" id="isPasted">Global EV Outlook</a>), the share of electric vehicles (EVs) in the overall car market has risen from around 4% in 2020 to 14% in 2022 and is set to increase further to 18% in 2023. There is no doubt that demand for EVs is booming, and sales are set to surge to another record total this year.Government incentives, consumer behavior, and improvements in EV technology have all driven this significant growth. Governments around the world have introduced policies to encourage EV adoption. Consumer awareness has evolved, with increased demand for greener technologies and sustainable mobility modes. Battery technology also continues to improve, leading to longer driving ranges on a single charge. Finally, charging infrastructure is expanding rapidly to support the growing number of EVs on the road.New Parts but the Same Need for Quality ControlOEMs and part manufacturers who were used to producing traditional internal combustion engine (ICE) vehicles must now adapt to this sea change. The pivot from ICE to EV will disrupt the entire supply chain. As new parts must be developed and produced, the process of electrification will create a significant shift in market size for automotive components.Throughout all these changes, part quality must remain impeccable. Each part must comply with the highest quality standards and meet the tightest tolerances while also meeting the production throughput specifically required by the automotive industry.<h2>Some Challenges Awaiting EV Part Manufacturers</h2>Measuring Reflective MaterialsThe parts used in making EVs, such as the battery tray, are typically made from lightweight and durable materials like aluminum, steel, or composite materials, which are mostly reflective. Any measurement technology involving white or blue light is sensitive to surface finishes and may require surface preparation (in the form of powder application) to perform inspections properly. Such treatment means one more step in the inspection process, which means more time to manufacture and deliver the parts.Inspecting EV Parts While Increasing ThroughputTraditional inspection methods usually take time. Coordinate measuring machines (CMMs) are located in dedicated metrology labs, necessitating a lot of programming, setup, and back-and-forth with the production line. CMMs are not the fastest inspection tools and require metrology experts to operate them. In addition, they are often in high demand, busy with all types of inspections. All these extra steps congest and slow the inspection process, impairing the production throughput.Controlling Large and Complex PartsThe battery tray is the EV’s main structural part. Therefore, the trays are&nbsp;<a href="https://www.creaform3d.com/en/handyscan-3d-max-series-for-large-objects" target="_blank">large in size</a>, and a single person cannot move them easily. Moreover, they are produced in harsh environments with ubiquitous oscillations, vibrations, and thermal variations—not ideal for performing highly accurate measurements. On top of that, they also feature extrusions that can be laborious to measure with traditional tools.Solution: Accuracy on the Shop FloorIdeally, auto part manufacturers need to be able to inspect their large and complex parts directly on the shop floor without compromising on accuracy or requiring surface preparation. Their metrology instrument must measure more quickly and require less training, handling, and programming time than CMMs, which will help accelerate inspection time and increase production throughput.<h2>Why Dura Automotive Systems Chose Creaform</h2>DURA Automotive Systems is a global automotive supplier specializing in the design, engineering, and manufacturing of solutions that drive the evolution of mobility. Fond of state-of-the-art technology and cutting-edge manufacturing processes, the company is known for its support of a well-known luxury automotive brand in joining the EV revolution.In its quest for the most advanced technology to meet its precision measurement needs, DURA Auto has chosen Creaform for its additional measuring capacity, portability, and flexibility. Armed with the MetraSCAN 3D and HandyPROBE (paired with Polyworks), the engineers can achieve precision tolerances for the most demanding product specifications.<iframe width="640" height="360" src="https://www.youtube.com/embed/uwaPeHpu-NA?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>In addition, the unmatched speed and portability of the measuring instruments contributed to reducing the inspection time, which impacted the overall efficiency of the manufacturing process and the production throughput.&nbsp;We use the Creaform MetraSCAN 3D and HandyPROBE as portable measurement stations to measure incoming extrusions and get quick scans of the product before it moves forward to a mill to ensure the mill will accept the part. Thanks to Creaform, we have increased our capacity by 75%.-Branden Head, Metrology Supervisor at Dura AutomotiveThe distinct performance obtained with Creaform and Polyworks has confirmed their strong reputation in the 3D measurement industry. “Creaform and its 3D measurement solutions were pivotal for the measurement capability in our facility,” adds Mr. Head. “Our project would have struggled with capacity and mobility without Creaform’s and Polyworks’s technology.”&nbsp;&nbsp;Solution: Automated Quality ControlAutomated quality control (AQC) systems are becoming a key strategy for increasing inspection efficiency and production throughput without sacrificing measurement accuracy. No matter the production type—high mix/low volume or low mix/high volume—AQC solutions can be integrated within a production line quickly and without any lengthy training or significant downtimes. They will automatically slash data acquisition times from hours to mere minutes, all while ensuring manufacturers feel confident that the EV parts are approved according to tight tolerances and industry regulations.<a href="https://www.creaform3d.com/en/solutions/automated-quality-control-key-strategy-e-car-manufacturers-speed-their-throughput" target="_blank">Why Walter Automobiltechnik Turned to Creaform</a>Walter Automobiltechnik GmbH is a renowned German part and accessory supplier for big OEMs in the automotive and motorcycle industries. Over the past few years, skyrocketing demand from OEMs for new EV parts drove the company to look for an alternative inspection approach to improve its part quality and productivity. In particular, Walter Automobiltechnik wanted a solution to replace its manual methods and traditional CMM in producing an EV engine mount for BMW’s new fully electric Mini Cooper SE.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1702552632466-000035.webp" style="width: 300px;" class="fr-fic fr-dib">Looking to assess the quality of its EV engine mounts and maintain a short cycle time, Walter Automobiltechnik turned to Creaform’s R-Series. The metrology team implemented the MetraSCAN 3D-R, a powerful robot-mounted optical scanner, into two custom, automated industrial measuring cells at the end of the production line. VXelements, Creaform’s fully integrated 3D software platform, was also chosen to conduct the inspections.With the MetraSCAN 3D-R’s high measurement rate, Walter Automobiltechnik drastically reduced its inspection time from one hour and 30 minutes to just eight minutes per mount—all with an accuracy of 0.05 mm. Undoubtedly, Walter Automobiltechnik could not have achieved that level of throughput with a traditional CMM. “In the future, we think this system is a must-have in the automotive industry,” said Tommy Laukdrej, Head of Quality Management at Walter Automobiltechnik.Faster Inspection Time for Higher Production ThroughputAny proven and trusted method that accelerates inspection time will lead to higher production throughput. Whether automotive parts manufacturers are performing inspections directly on the shop floor or automating the inspection process without compromising on accuracy, they have everything to gain from considering portable or automated 3D scanning solutions. On top of that, their increased efficiency will greatly please their customers.

Based on the latest International Energy Agency (IEA) projections (featured in the newest edition of the Global EV Outlook), the share of electric vehicles (EVs) in the overall car market has risen from around 4% in 2020 to 14% in 2022 and is set to increase further to 18% in 2023.

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